Chevrolet - Silverado 1500 2wd - Workshop Manual - 2006 - 2006

Factory Workshop Manual Make Chevrolet Model Silverado 1500 2wd Engine and year V8-4.8L VIN V (2006) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 16 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 17 Alarm Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 18 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 19 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 21 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 22 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 23 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 24 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 25 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 26 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 28 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 29 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 30 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 31 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 32 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 33 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 34 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 35 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 36 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 38 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 40 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 41 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 42 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 43 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 44 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 45 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 46 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 47 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 48 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 49 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 50 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 51 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 52 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 53 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 54 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 55 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 57 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 58 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 59 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 60 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 61 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 62 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 63 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 64 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 65 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 66 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 67 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 68 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 69 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 70 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 71 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 72 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 73 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 74 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 76 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 77 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 86 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 87 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 88 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 94 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 95 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 96 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 105 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 110 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 115 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 120 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 121 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 127 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 136 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 145 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 154 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 159 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 160 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 165 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 166 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 167 Method 1 Method 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 168 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 174 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 175 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 176 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 177 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 183 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 184 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 185 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 186 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations Instrument Panel (I/P) - Right Rear Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 190 Global Positioning System Module: Diagrams Vehicle Communication Interface Module (VCIM) - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 191 Vehicle Communication Interface Module (VCIM) - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 192 Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the Instrument Panel (I/P) upper trim panel. IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 2. Fully open the I/P storage compartment. 3. Disconnect the electrical connectors (2) from the Vehicle Communication Interface module (VCIM) (1). 4. Disconnect the coaxial cable (3) from the VCIM. 5. Remove the screws (1, 3) from the passenger side upper I/P support (2). 6. Remove the passenger side upper I/P support (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 193 7. Remove the screw (1) retaining the VCIM bracket to the I/P. 8. Remove the retainer from the VCIM bracket. 9. Remove the nuts holding the mounting brackets to the VCIM. 10. If necessary, move the cross-car duct forward slightly in order to make room for the removal of the module. 11. Remove the VCIM and bracket assembly from the I/P. 12. Remove the nuts (4) from the VCIM mounting brackets (2). 13. Remove the mounting brackets (2) from the VCIM (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 194 INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Ensure the nuts (3) are installed on the module mounting brackets (3). 3. Install the mounting brackets (2) to the VCIM (1). 4. Install the nuts (4). Tighten the nuts to 2 N.m (18 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 5. If necessary, move the cross-car duct forward slightly in order to make room for the installation of the module. 6. Install the VCIM and bracket assembly to the I/P. 7. Install the push in retainer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 195 8. Install the VCIM screw (1) to the I/P. Tighten the screws to 2 N.m (18 lb in). 9. Install the passenger side upper I/P bracket (2). 10. Install the I/P upper bracket screws (3). Tighten the screws (3) to 2 N.m (18 lb in). 11. Install the I/P upper bracket screws (1). Tighten the screws (1) to 50 N.m (37 lb ft). 12. Connect the coaxial cable (3) to the VCIM. 13. Connect the electrical connectors (2) to the VCIM. 14. Install the I/P trim panel. 15. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 196 system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 16. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 17. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 18. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 1. Tell the advisor that this vehicle has received a new VCIM. 2. Ask the advisor to add the new STID and the ESN to update the customer's account. 3. Follow any additional instructions from the OnStar(R) advisor. 4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. 19. The default language for voice recognition in the generation 5 OnStar(R) module is English. To change the language resident in the module, refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 205 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 206 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 207 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 213 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 214 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 215 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) Door Module: Diagrams Driver Door Module (DDM) Driver Door Module (DDM) - C1 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 221 Driver Door Module (DDM) - C2 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 222 Driver Door Module (DDM) - C3 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 223 Driver Door Module (DDM) - C4 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 224 Driver Door Module (DDM) - C5 (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 225 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 226 Door Module: Diagrams Passenger Door Module (PDM) Passenger Door Module (PDM) - C1 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 227 Passenger Door Module (PDM) - C2 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 228 Passenger Door Module (PDM) - C3 (With RPO Code YE9) Passenger Door Module (PDM) - C4 (With RPO Code YE9) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 229 Passenger Door Module (PDM) - C5 (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module (DDM) > Page 230 Passenger Door Module (PDM) - C5 (Heated Seat Switch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Page 234 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. 4. Install the module retaining screws (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure . Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 238 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 239 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 243 Sunroof / Moonroof Module: Diagrams Sunroof Control Module C1 Sunroof Control Module C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 244 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 254 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 260 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 261 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) 1 - Electronic Brake Control Module (EBCM) 2 - Electronic Brake Control Module (EBCM) Electrical Connector - C1 3 - Electronic Brake Control Module (EBCM) Electrical Connector - C2 4 - Frame Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) C1 Electronic Brake Control Module (EBCM) C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) C1 > Page 264 Electronic Brake Control Module (EBCM) C2 (8600 GVW Or Less W/Rear Disc Brakes) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) C1 > Page 265 Electronic Brake Control Module (EBCM) C2 (Greater Than 8600 GVW Or Rear Drum Brakes) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 266 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precaution. Important: After installation, calibrate the new electronic brake control module (EBCM) to the tire size that is appropriate to the vehicle. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the electric hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Remove the mounting screws (1) that fasten the EBCM (2) to the brake pressure modulator valve (BPMV) (3). 5. Remove the EBCM from the BPMV. Removal may require a light amount of force. 6. Remove the EBCM from the vehicle. 7. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 267 1. Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM to the BPMV. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the new EBCM screws (1). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Lower the vehicle. 4. Connect the negative battery cable. 5. If a new EBCM was installed, the EBCM must be programmed. 6. Turn the ignition to the ON position. DO NOT start the engine. 7. Perform the Diagnostic System Check - Vehicle . See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 281 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Radiator Cooling Fan Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 285 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 311 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 312 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 313 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 314 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 315 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 316 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 317 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 318 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 319 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 320 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 322 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 323 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 324 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 325 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 326 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 327 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 328 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 329 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 330 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 331 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 332 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 333 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 334 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 335 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 336 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 337 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 338 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 339 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 341 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 342 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 346 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 347 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 350 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 351 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 352 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 353 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 354 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 355 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 357 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 358 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Radiator Cooling Fan Motor Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 373 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 374 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 376 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 377 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 378 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 380 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 382 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 383 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 384 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 385 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 386 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 387 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 388 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 389 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 390 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 391 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 392 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 393 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 394 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 395 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 396 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 397 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 398 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 399 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 400 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 401 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 402 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 403 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 404 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 405 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 406 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 407 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 408 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 409 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 410 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 411 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 412 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 413 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 414 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 415 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 416 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 418 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 419 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module (CCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 424 Cruise Control Module (CCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 438 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 439 Blower Motor Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 443 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 444 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 445 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 446 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 447 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 448 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 449 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 450 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 451 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 452 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 453 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 454 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 455 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 456 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 457 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 458 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 459 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 460 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 461 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 463 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 464 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 465 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 466 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 467 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 468 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 469 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 470 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 471 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 472 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 473 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 474 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 475 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 476 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 477 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 478 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 479 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 480 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 481 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 482 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 483 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 484 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 485 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 486 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 487 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 488 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 489 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 490 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 491 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 492 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 493 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 494 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 495 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 496 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 497 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 498 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 499 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 503 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 504 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 505 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 506 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 507 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 516 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 517 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 523 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 529 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 530 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 535 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 541 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 547 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 548 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 549 HVAC Control Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 553 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 555 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 556 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 557 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 558 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 559 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 560 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 561 Control Module HVAC: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 562 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 563 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 564 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 565 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 566 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 567 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 568 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 569 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 570 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 571 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 572 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 573 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 574 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 575 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 576 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 577 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 578 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 579 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 580 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 581 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 582 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 584 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 585 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 586 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 587 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 588 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 589 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 590 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 591 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 592 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 593 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 594 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 595 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 596 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 597 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 598 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 599 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 600 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 601 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 602 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 603 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 604 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 605 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 606 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 607 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 608 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 609 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 610 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 611 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 612 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 613 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 614 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 615 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 616 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 617 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 618 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 619 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 620 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 621 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 622 Control Module HVAC: Connector Views HVAC Control Module - C1 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 623 HVAC Control Module - C1 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 624 HVAC Control Module - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 625 Blower Motor Control Processor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC Systems - Manual Control Module HVAC: Service and Repair HVAC Systems - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 1. Release the retaining tabs. 2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control assembly. IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. 4. Install the screws from the HVAC control assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.9 N.m (17 lb in). 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. 7. Start the vehicle and let run for one minute. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC Systems - Manual > Page 628 Control Module HVAC: Service and Repair HVAC Systems - Automatic BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE 1. Install the blower motor control processor (2) to the HVAC module (1). 2. Install the blower motor control processor retaining screws. Tighten the screws to 1.6 N.m (14 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the electrical connector (4) to the blower motor control processor (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC Systems - Manual > Page 629 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 634 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 635 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 636 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 637 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label Fog/Driving Lamp Relay: Locations Fuse Block - I/P Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 642 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 643 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 644 Fog/Driving Lamp Relay: Locations Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 645 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 646 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 647 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fuse Block - I/P Label > Page 648 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 652 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 653 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 654 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 655 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 659 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 660 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 661 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 662 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 666 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 667 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 668 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 669 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 673 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 674 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 675 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 676 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 681 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 682 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 Relay Box: Diagrams Relay Block - I/P C1 Relay Block - I/P C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 687 Relay Block - I/P C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 688 Relay Block - I/P C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 689 Relay Block - I/P C3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 690 Relay Block - I/P C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 691 Relay Block - I/P C5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 692 Relay Box: Diagrams Relay Block - I/P C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 693 Relay Block - I/P C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 694 Relay Block - I/P C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 695 Relay Block - I/P C3 Relay Block - I/P C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 696 Relay Block - I/P C5 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 697 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Relay Block - I/P C9 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 698 Relay Block - I/P C10 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 699 Junction Block - I/P Wire Entry (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 700 Junction Block - I/P Wire Entry (Part 2) Junction Block - I/P - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 701 Junction Block - I/P - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 702 Junction Block - I/P - C5 Junction Block - I/P - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 703 Junction Block - I/P - C7 Junction Block - I/P - C8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 704 Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 705 Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 706 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 707 Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label Relay Box: Application and ID Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 710 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 711 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 712 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 713 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 714 Relay Box: Application and ID Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 715 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 716 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 717 Relay Box: Application and ID Fuse Block - I/P Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 718 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 719 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 720 Relay Box: Application and ID Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 721 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 722 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 723 Relay Box: Application and ID Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 724 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 725 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 726 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 727 Location View Fuse Block - Underhood - Cooling Fan (10 Series) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 728 Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 729 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 730 Location View Fuse Block - I/P Label Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 731 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 732 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 733 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 734 Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 735 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 736 Location View Junction Block - I/P Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 737 Location View Junction Block - Rear Lamps Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 738 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 741 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 742 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 743 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 744 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 745 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 746 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module (BCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 754 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 755 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 757 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 761 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 762 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Body Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 768 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 770 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 777 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 778 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 780 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 781 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 782 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 784 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 787 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 788 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 789 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 790 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 791 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 792 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 793 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 794 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 795 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 796 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 797 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 798 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 799 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 800 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 801 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 803 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 804 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 805 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 806 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 807 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 808 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 809 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 810 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 811 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 812 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 813 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 814 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 815 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 816 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 817 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 818 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 819 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 820 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 822 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 823 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 825 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Splice Pack - SP205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 834 Splice Pack - SP207 (Without RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Splice Pack - SP207 (With RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Body Control Module: Electrical Diagrams Door Control Module Diagrams Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Body Control System Diagrams Body Control System Schematics Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Power, Ground, and Serial Data Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Interior Lights and Interior Lights Dimming References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Headlights and Exterior Lights References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Controlled/Monitored Subsystem References - 1 of 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Controlled/Monitored Subsystem References - 2 of 2 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 847 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the Body Control Module (BCM) fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the Powertrain Control Module (PCM). If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 848 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 851 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with Class 2 Device - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with High Speed GMLAN Device - Power Mode Mismatch See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Retained Accessory Power (RAP) On After Time-Out - Retained Accessory Power (RAP) Inoperative See: Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 852 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 853 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 854 Body Control Module: Service and Repair BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 855 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 864 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 870 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 875 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 876 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 877 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 882 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 883 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 884 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 889 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 899 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 904 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 905 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 906 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 911 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 912 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 913 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 918 Powertrain Control Module (PCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 929 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Engine Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 932 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 933 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 934 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 935 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 937 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 944 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 945 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 947 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 948 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 949 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 951 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 954 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 955 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 956 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 957 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 958 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 959 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 960 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 961 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 962 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 963 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 964 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 965 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 966 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 967 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 968 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 970 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 971 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 972 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 973 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 974 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 975 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 976 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 977 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 978 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 979 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 980 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 981 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 982 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 983 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 984 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 985 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 986 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 987 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 989 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 990 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Powertrain Control Module (PCM) C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Powertrain Control Module (PCM) C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Powertrain Control Module (PCM) C2 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Powertrain Control Module (PCM) C2 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Powertrain Control Module (PCM) C2 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 999 - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 1000 Engine Control Module: Description and Operation Throttle Actuator Control (TAC) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 1001 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 1002 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NOS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 1003 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: - Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 1004 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 1005 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary Fuel Pump Relay: Locations Primary Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 1011 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 1012 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 1013 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 1014 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 1015 Fuel Pump Relay - Secondary (Except RPO Code NQZ) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1018 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1019 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1020 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1021 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1022 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1023 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1024 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1025 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1026 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1027 Fuel Pump Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1028 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1029 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1030 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1031 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1032 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1033 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1034 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1035 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1036 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1037 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1038 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1039 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1040 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1041 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1042 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1043 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1044 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1050 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1051 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1052 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1093 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1094 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1095 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1096 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1097 Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test (Non-HP2) Battery Inspection/Test (HP2) in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1098 Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1099 Step 8 - Step 17 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1100 Step 18 - Step 26 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1101 Step 27 - Step 31 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Below Driver Seat - SIR Wiring Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1106 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1107 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1108 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1109 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Removal Procedure Caution: Refer to SIR Caution in the Preface section. Caution: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. 2. Remove the driver seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint SDM wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. Important: The following repair procedures should only be used in the event that the inflatable restraint SDM mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 11514463 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1110 10.7. Install a new fastener GM P/N 03530297. Installation Procedure 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. Notice: Refer to Fastener Notice in the Preface section. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint SDM wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint SDM. 9. Install the door sill plate. Refer to Front Side Door Sill Trim Plate Replacement. 10. Install the driver seat. Refer to Front Seat Replacement - Bucket. Important: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling. Important: Use the scan tool to perform the vehicle theft deterrent (VTD) relearn. Do not use the 30 minute manual learn procedure. 12. Reprogram the VTD system. 13. Refer to Control Module References for programming and setup information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System Relay > Component Information > Locations A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1118 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1119 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1120 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1121 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Page 1128 Tire Pressure Module: Service and Repair Control Module Setup Passenger Door Module (PDM) Setup After passenger door module (PDM) switch assembly replacement, the following procedures must be performed in the order that they appear for the Tire Pressure Monitor (TPM) System to function properly. The PDM also requires keyless entry transmitter programming after replacement. Refer to Transmitter Synchronization. TPM System Enable The service replacement PDM switch assembly comes with the TPM System disabled to allow the same part number PDM to be used in both TPM and non-TPM equipped vehicles. Once the TPM option is enabled in the PDM, it cannot be disabled. Before proceeding with the steps below, ensure the vehicle is equipped with TPM (UJ6). Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Chassis. 4. Select Tire Pressure Monitor. 5. Select Special Functions. 6. Select TPM Option Enable. 7. Press the exit key to escape. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Chassis. 4. Select Tire Pressure Monitor. 5. Select Special Functions. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle driver door placard sticker. 9. Select the rear tire pressure as noted on the vehicle driver door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After PDM switch assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the PDM memory. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 1139 Control Module: Diagrams Automatic Transmission Related Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 1140 Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 1141 Transmission Control Module (TCM) 80-Way Connector Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 1142 Control Module: Service and Repair Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module (TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 1143 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Connect the negative battery cable. 6. Reprogram the TCM. Refer to Control Module References in Computer/Integrating Systems. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1148 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1149 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1150 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1151 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 1157 Passlock Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Door Lock Switch - Passenger (Base Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch Replacement - Door Lock and Side Window - Driver Power Door Lock Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch Replacement - Door Lock and Side Window - Driver > Page 1168 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch Replacement - Door Lock and Side Window - Driver > Page 1169 Power Door Lock Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Remove the screw (2) that retains the switch panel bezel (1) to the front door trim panel. 3. Remove the switch panel bezel from the door panel using a flat-bladed tool. 4. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 5. Remove the door module from the switch panel bezel. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch Replacement - Door Lock and Side Window - Driver > Page 1170 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module into the door trim panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw (2) that retains the switch panel bezel (1) to the front door trim panel. Tighten the screw (2) to 2 N.m (18 lb in). 4. Install the front door trim panel. 5. Perform the necessary setup and programming procedures. Refer to Door Control Module Programming and Setup in Vehicle Control Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Driver Seat (Part 2) With RPO Code AG1 And AN3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 1174 Driver Seat (Part 1)With RPO Code AG1 And AN3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor > Page 1177 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor > Page 1178 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor > Page 1179 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor > Page 1180 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor > Page 1181 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor > Page 1182 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1191 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1197 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 1203 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 1204 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 1205 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 1215 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 1216 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 1217 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1222 Power Seat Switch: Locations Passenger Seat (Part 1) With RPO Code AG2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1223 Driver Seat (Part 1)With RPO Code AG1 And AN3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1224 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1225 Seat Adjuster Switch - Driver (With RPO Code AG1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1226 Seat Adjuster Switch - Passenger (with RPO Code AN3) Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Seat Bolster/Lumbar Switch - Passenger (With RPO Code AN3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. 2. Install the lumbar switch screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the power seat switch bezel from the seat. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1229 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1230 Power Seat Switch: Removal and Replacement Seat Switch Bezel Replacement Seat Switch Bezel Replacement Removal Procedure 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. Installation Procedure 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1231 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Passenger Door Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 1237 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. 2. Install the retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Service and Repair > Memory Seat Calibration Procedure Seat Memory Switch: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 1242 Seat Memory Switch: Service and Repair Memory Seat Switch Replacement MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1246 Sunroof Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1247 Sunroof / Moonroof Switch: Service and Repair SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the roof console assembly. 2. Disconnect the electrical connector. 3. Remove the switch by unsnapping from roof console assembly. INSTALLATION PROCEDURE 1. Install the switch to roof console assembly by snapping into place. 2. Connect the electrical connector. 3. Install the roof console assembly. 4. Synchronize the sunroof motor. Refer to Sunroof Motor/Actuator Synchronization. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Hydraulic Brakes Component Views Brake Fluid Level Switch (Except JC4) 1 - Hydraulic Brake Line 2 - Bracket for Chassis Harness Studs 3 - LH Front Lower Dash Panel 4 Bracket for Chassis Harness 5 - Inline Connector 6 - Inline Connector 7 - Fuse Block-Underhood Connector 8 - Fuse Block-Underhood Eyelet Connector 9 - Brake Fluid Level Switch Connector 10 - Brake Fluid Level Switch 11 - Brake Fluid Reservoir Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1252 Brake Fluid Level Switch (except JC4) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Hydraulic Brakes Component Views Brake Pressure Differential Switch (JC4) 1 - Supplemental Brake Assist Pump Motor 2 - Chassis Harness 3 - Brake Pressure Differential Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 1256 Brake Pressure Differential Switch (JC4) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Hydraulic Brakes Component Views Park Brake Switch 1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowel Side Inner Panel Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1260 Park Brake Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch (NW7) 1 - Traction Control Switch 2 - Instrument Panel Outer Air Outlet Housing Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1264 Traction Control Switch (NW7) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1265 Traction Control Switch: Service and Repair Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove the instrument panel (I/P) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the I/P assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1266 2. Install the stabilitrak switch (3) into the I/P assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install the I/P bezel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1275 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1281 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1282 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF 1 - Wheel Speed Sensor (WSS) - RF 2 - Wheel Speed Sensor (WSS) - LF Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) LF Wheel Speed Sensor (WSS) LF Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) LF > Page 1285 Wheel Speed Sensor (WSS) RF Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1286 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front (2 Wheel Drive) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 Series. 4. Remove the wheel speed sensor (WSS) cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1287 8. Remove the WSS mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the WSS (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1288 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1289 9. Connect the WSS cable electrical connector. 10. Install the brake rotor (2) shown on the 1500 Series. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1300 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1301 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1302 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1303 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1309 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1310 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1311 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1312 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1313 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1314 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1315 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1316 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level sensor to the oil pan. ^ Tighten the sensor to 13 Nm (115 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 1321 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 1331 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions Ambient Temperature Sensor / Switch HVAC: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Ambient Temperature Sensor / Switch HVAC: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 Ambient Air Temperature Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 1409 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams Air Temperature Sensor Assembly - Inside Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 1413 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 1414 7. Install the left windshield garnish molding. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1418 Air Temperature Sensor - Lower Left Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1419 Air Temperature Sensor - Lower Right Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1420 Discharge Air Temperature Sensor / Switch: Diagrams Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1421 Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right > Page 1424 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right > Page 1425 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right > Page 1426 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 1432 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1433 Low Pressure Sensor / Switch: Locations A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1434 A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1435 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch A/C Low Pressure Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1436 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Ambient Light Sensor (With RPO Code CJ3) Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1440 Ambient Light/Sunload Sensor Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1441 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System Fuel Gauge Sender: Description and Operation Fuel System FUEL SENDER ASSEMBLY The front fuel sender on dual tank applications consists of the following major components: - The fuel level sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter The rear fuel sender on dual tank applications consists of the following major components: - The fuel level sensor (4) - The FTP sensor (1) - The rear fuel pump (2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System > Page 1450 The fuel sender assembly on single tank applications consists of the following major components: - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System > Page 1451 Fuel Gauge Sender: Description and Operation Fuel System (Cab Chassis) FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: The fuel sender assembly (2) - The fuel strainer (3) - The fuel pump (4) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1452 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1453 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1454 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams Ambient Air Temperature Sensor (With RPO Code DF5) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams > Page 1458 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Hydraulic Brakes Component Views Park Brake Switch 1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowel Side Inner Panel Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1462 Park Brake Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ambient Light Sensor: Diagrams Ambient Light Sensor (With RPO Code CJ3) Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1467 Ambient Light/Sunload Sensor Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1468 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > NV 3500 - Manual Transmission Backup Lamp Switch: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > NV 3500 - Manual Transmission > Page 1473 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > NV 3500 - Manual Transmission > Page 1474 Backup Lamp Switch: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > NV 3500 - Manual Transmission > Page 1475 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > NV 3500 - Manual Transmission > Page 1476 Backup Lamp Switch: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > NV 3500 - Manual Transmission > Page 1477 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1478 Backup Lamp - Switch (M/T) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 - Manual Transmission Backup Lamp Switch: Service and Repair NV 3500 - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 1481 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 1482 Backup Lamp Switch: Service and Repair NV 4500 - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 1483 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 1484 Backup Lamp Switch: Service and Repair ZF S6-650 - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure 1. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 1485 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Stop Lamp Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1489 Stop Lamp Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1490 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations > Page 1494 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Turn Signal Multifunction Switch - C1 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Page 1498 Turn Signal Multifunction Switch - C3 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement - Rear Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement - Rear > Page 1504 Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement - Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1511 Headlamp Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1512 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Wheel And Column Sub-System Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1516 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to Servicing the SIR System Caution in Service Precautions. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the horn plunger to the steering column. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1517 4. Install the inflator module. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1521 Turn Signal Multifunction Switch - C3 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1522 Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the upper and lower trim covers. 3. Remove the wire harness assembly (1) from the wire harness strap (2). Important: The abrasion sleeve located on the steering column wire harness assembly must be reinstalled. Make note of what connector is coming out of the abrasion sleeve for installation purposes. 4. Disconnect the turn signal and multifunction switch assembly connector from the SIR system coil connector. 5. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly out of the bulkhead connector (1). 6. Remove the 2 pan head tapping screws (1) and (3) from the turn signal and multifunction switch assembly (2). 7. Remove the turn signal and multifunction switch assembly (2) from the steering column tilt head assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1523 Installation Procedure 1. Install the turn signal and multifunction switch assembly (2) onto the steering column tilt head assembly. 2. Screw the 2 pan head tapping screws (1) and (3) into the turn signal and multifunction assembly (2). ^ Tighten the top pan head tapping screw (1) to 3 Nm (27 inch lbs.) for Domestic Column Shift. ^ Tighten the top pan head tapping screw (1) to 7 Nm (62 inch lbs.) for Domestic Floor Shift and Export Column Shift. ^ Tighten the side pan head tapping screw (3) to 7 Nm (62 inch lbs.) for all. Notice: Refer to Fastener Notice in Service Precautions. Important: Be sure that the electrical contact of the turn signal and multifunction switch assembly (2) rests on the turn signal cancel cam assembly. 3. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly into the bulkhead connector (1). 4. Connect the turn signal and multifunction switch assembly connector to the SIR coil connector. 5. Install the wire harness assembly (1) into the wire harness strap (2). Important: The abrasion sleeve must be installed back onto the steering column wire harness assembly. The ignition lock cylinder case wires and connector must be hanging out of the middle of the abrasion sleeve. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1524 6. Install the upper and lower trim covers. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1530 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1531 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1532 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1533 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1534 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1549 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1550 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1551 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1552 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1553 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1562 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1563 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1564 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1601 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1602 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1603 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1604 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1605 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1606 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1607 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1608 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1609 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1610 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1611 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1612 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Current Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1620 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1634 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1635 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1636 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1637 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1638 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1639 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1640 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1641 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1642 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1645 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1646 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1647 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1648 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1649 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1650 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1651 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1690 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1691 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1692 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission Clutch Switch: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 1697 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 1698 Clutch Switch: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 1699 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 1700 Clutch Switch: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 1701 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1710 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1711 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1712 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1713 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1719 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1720 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1721 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1722 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1723 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1724 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1725 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1726 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1794 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1795 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1796 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1797 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1802 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1805 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1806 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1810 Fuel Level Sensor: Application and ID FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1811 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement 2 FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 1814 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 1815 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 1816 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT (4.8L, 5.3L, AND 6.0L ENGINES) REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1820 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1821 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1822 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1826 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1827 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1828 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1905 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1906 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1907 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1911 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1912 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1913 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 1920 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors (HO2S) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 Oxygen Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1947 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1948 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1949 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1950 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1951 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1952 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1953 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1954 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1955 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1987 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1988 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1989 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1990 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1991 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1992 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1993 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1994 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1995 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1996 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1999 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2000 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2001 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2002 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2003 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2004 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2005 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2010 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2066 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2067 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2068 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2069 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2070 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2071 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2072 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2073 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2074 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2075 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2076 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2083 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2084 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2087 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2090 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2093 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2094 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2095 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2096 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2097 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2098 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2103 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2104 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2105 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2106 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2107 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2174 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2176 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2184 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2185 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2336 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2337 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2412 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2413 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2416 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2417 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 2424 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 3. Lower the hush and knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Console. 4. Remove the steering column trim covers. 5. With the key installed, turn the key to the RUN position. 6. Install an allen wrench into the hole on top of the lock cylinder housing. Push down on the allen wrench to release the tab on the lock cylinder inside the lock cylinder housing. 7. Slide the lock cylinder out of the lock cylinder housing. Installation Procedure 1. Install the key into the lock cylinder. 2. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 2425 Important: The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN. 3. Align the lock cylinder and install into the lock cylinder housing. 4. Install the steering column trim covers. 5. Install the hush and knee bolster. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 7. Connect the negative battery cable. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 2426 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the ignition switch. 3. Remove the turn signal cancel cam. 4. Remove the park lock cable from the lock cylinder housing. 5. Remove 3 TORX(r) screws. 6. Remove the lock cylinder housing from the steering column. Installation Procedure 1. Install 3 TORX screws into the lock cylinder housing. ^ Tighten the TORX screws to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the turn signal cancel cam. 3. Install the park lock cable into the lock cylinder housing. 4. Install the ignition switch. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2432 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2433 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2447 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2450 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2451 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2452 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2453 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2454 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2455 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2456 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2457 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2458 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2459 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2460 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2461 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2462 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2463 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2464 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2465 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2466 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2467 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2468 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2469 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2470 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2471 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2472 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2503 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2504 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2505 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Center Of The I/P - Accessory Switches (Except 10 Searies And Crew Cab) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2510 Inflatable Restraint I/P Module Disable Switch (Except 10 Series And Crew Cab) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > I/P Module Disable Switch (HD Model Pickups) Air Bag Deactivation Switch: Description and Operation I/P Module Disable Switch (HD Model Pickups) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > I/P Module Disable Switch (HD Model Pickups) > Page 2513 Air Bag Deactivation Switch: Description and Operation I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 2514 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel trim bezel. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Front End Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor Impact Sensor: Diagrams Inflatable Restraint Front End Sensor Inflatable Restraint Front End Sensor - Left (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2520 Inflatable Restraint Front End Sensor - Right (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2521 Inflatable Restraint Front End Sensor (With RPO Code HVY) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2522 Inflatable Restraint Side Impact Sensor (SIS) - Right Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2523 Inflatable Restraint Passenger Seat Belt Tension Retractor Sensor (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2524 Inflatable Restraint Passenger Presence System (PPS) Sensor (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Passenger Seat Belt Tension Retractor Sensor Impact Sensor: Description and Operation Passenger Seat Belt Tension Retractor Sensor INFLATABLE RESTRAINT PASSENGER SEAT BELT TENSION RETRACTOR SENSOR The seat belt tension retractor sensor is used to enhance the passenger presence system (PPS) when an infant car seat is properly restrained on the front outboard passenger seat. The seat belt tension retractor sensor is a 3-wire potentiometer mounted on the lower seat belt anchor and provides an input to the PPS module. When an infant car seat is properly restrained on the front passenger seat, the seat belt is tightly secured through the infant car seat. The seat belt pulls on the tension sensor and changes the voltage signal to the PPS module. The PPS module uses the voltage signal to help determine if a tightly belted infant car seat is installed. The PPS uses the inputs from the seat belt tension retractor sensor and the PPS pressure sensor to determine if the I/P module should be suppressed or enabled. The PPS monitors the seat belt tension retractor sensor circuits and sets DTC 023 if a fault is detected. To determine what DTCs have been set by the PPS, the Tech 2 is used to command the SDM to request the PPS to flash the DTCs using the PASSENGER AIR BAG ON/OFF indicators located on the rearview mirror. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Passenger Seat Belt Tension Retractor Sensor > Page 2527 Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). 2. Point the arrow on the sensor toward the front of the vehicle. IMPORTANT: Refer to SIR Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 2530 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Driver Seat Belt Buckle Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2534 Passenger Seat Belt Buckle (with RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2535 Seat Belt Buckle Switch: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2536 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Diagrams Inflatable Restraint Passenger Seat Belt Tension Retractor Sensor (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Diagrams > Page 2540 Seat Belt Tension Sensor: Description and Operation INFLATABLE RESTRAINT PASSENGER SEAT BELT TENSION RETRACTOR SENSOR The seat belt tension retractor sensor is used to enhance the passenger presence system (PPS) when an infant car seat is properly restrained on the front outboard passenger seat. The seat belt tension retractor sensor is a 3-wire potentiometer mounted on the lower seat belt anchor and provides an input to the PPS module. When an infant car seat is properly restrained on the front passenger seat, the seat belt is tightly secured through the infant car seat. The seat belt pulls on the tension sensor and changes the voltage signal to the PPS module. The PPS module uses the voltage signal to help determine if a tightly belted infant car seat is installed. The PPS uses the inputs from the seat belt tension retractor sensor and the PPS pressure sensor to determine if the I/P module should be suppressed or enabled. The PPS monitors the seat belt tension retractor sensor circuits and sets DTC 023 if a fault is detected. To determine what DTCs have been set by the PPS, the Tech 2 is used to command the SDM to request the PPS to flash the DTCs using the PASSENGER AIR BAG ON/OFF indicators located on the rearview mirror. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Diagrams Seat Position Sensor: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Diagrams > Page 2548 Inflatable Restraint Seat Position Switch - Right (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Diagrams > Page 2549 Seat Position Sensor: Description and Operation INFLATABLE RESTRAINT SEAT POSITION SENSORS (SPS) The seat position sensor (SPS) is used to determine the proximity of a front driver or passenger seat position with respect to the frontal air bag. The SPS interfaces with the SDM. The state of the SPS allows the SDM to disable stage 2 of the frontal air bag for a front seat that is forward of a forward/rearward point in seat track travel. The SPS is a Hall effect sensor that is mounted on the outboard seat track of both the driver and passenger seats. The seat track includes a metal bracket that shunts the SPS magnetic circuit creating 2 states of seat position. The shunted state represents a rearward seat position. The non-shunted state represents a forward position. The SPS provides 2 current ranges, one range for the shunted state and a second range for a non-shunted state. These 2 states are inputs to the SDM, state 1 (shunted) being the rearward threshold and state 2 (non-shunted) being the forward threshold. When the SDM receives input from a SPS that state 1 threshold is reached (seat is rearward) the SDM will not disable stage 2 deployment, if required by the deployment sensors. When state 2 threshold is reached (seat is forward) the SDM will disable stage 2 deployment on the side the seat is forward. The SDM monitors the SPS circuit and if a fault is detected the SDM will set codes B0083 or B0084 and defaults to disabling stage 2 frontal deployment. This will only default on the side of the vehicle the sensor has a fault. It's important to understand that the SPS is secondary to the passenger presence system (PPS) and the manual I/P module disable switch. If either one of these devices are in the disable mode, the passenger air bag will not deploy regardless of the SPS status. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Diagrams > Page 2550 Seat Position Sensor: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Passenger Presence Components - Under Front Passenger Seat Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2554 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2555 Inflatable Restraint Seat Position Switch - Right (With RPO Code ALO) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2556 Seat Sensor/Switch: Description and Operation INFLATABLE RESTRAINT SEAT POSITION SENSORS (SPS) The seat position sensor (SPS) is used to determine the proximity of a front driver or passenger seat position with respect to the frontal air bag. The SPS interfaces with the SDM. The state of the SPS allows the SDM to disable stage 2 of the frontal air bag for a front seat that is forward of a forward/rearward point in seat track travel. The SPS is a Hall effect sensor that is mounted on the outboard seat track of both the driver and passenger seats. The seat track includes a metal bracket that shunts the SPS magnetic circuit creating 2 states of seat position. The shunted state represents a rearward seat position. The non-shunted state represents a forward position. The SPS provides 2 current ranges, one range for the shunted state and a second range for a non-shunted state. These 2 states are inputs to the SDM, state 1 (shunted) being the rearward threshold and state 2 (non-shunted) being the forward threshold. When the SDM receives input from a SPS that state 1 threshold is reached (seat is rearward) the SDM will not disable stage 2 deployment, if required by the deployment sensors. When state 2 threshold is reached (seat is forward) the SDM will disable stage 2 deployment on the side the seat is forward. The SDM monitors the SPS circuit and if a fault is detected the SDM will set codes B0083 or B0084 and defaults to disabling stage 2 frontal deployment. This will only default on the side of the vehicle the sensor has a fault. It's important to understand that the SPS is secondary to the passenger presence system (PPS) and the manual I/P module disable switch. If either one of these devices are in the disable mode, the passenger air bag will not deploy regardless of the SPS status. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2557 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Current Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 2568 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 3. Lower the hush and knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Console. 4. Remove the steering column trim covers. 5. With the key installed, turn the key to the RUN position. 6. Install an allen wrench into the hole on top of the lock cylinder housing. Push down on the allen wrench to release the tab on the lock cylinder inside the lock cylinder housing. 7. Slide the lock cylinder out of the lock cylinder housing. Installation Procedure 1. Install the key into the lock cylinder. 2. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 2569 Important: The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN. 3. Align the lock cylinder and install into the lock cylinder housing. 4. Install the steering column trim covers. 5. Install the hush and knee bolster. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 7. Connect the negative battery cable. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 2570 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the ignition switch. 3. Remove the turn signal cancel cam. 4. Remove the park lock cable from the lock cylinder housing. 5. Remove 3 TORX(r) screws. 6. Remove the lock cylinder housing from the steering column. Installation Procedure 1. Install 3 TORX screws into the lock cylinder housing. ^ Tighten the TORX screws to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the turn signal cancel cam. 3. Install the park lock cable into the lock cylinder housing. 4. Install the ignition switch. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Lock the steering column through the access hole in the lower trim cover using J 42640. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 3. Remove the steering column from the vehicle. Important: A new sensor must come with a pin installed. If pin is not installed, return and reorder sensor. Do not apply force to the sensor and the bearing assembly in a sideways direction. 4. Remove the sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 5. Remove the sensor retainer from the steering shaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2578 6. Pin diameter must be in the range of 1-2 mm. Important: When reusing the sensor (1) you must install a pin into the sensor before it is removed from the steering shaft. By not installing a pin into the sensor it will cause the sensor to lose its centering position and must be discarded. Do not remove the bearing adapter (3). If reusing the sensor (1), remove the position sensor by pulling the sensor straight out from the bearing adapter (3) until the sensor is almost off the steering shaft (2). Install a pin into the sensor before removing from the steering shaft (2). Do not remove the pin until the sensor is re-installed. 7. If replacing the sensor (1), remove the sensor by pulling the sensor straight out from the bearing adapter (3) and off the steering shaft. Installation Procedure 1. If reusing the sensor, with the pin still installed, align the sensor onto the steering shaft (2) and into the bearing adapter (3). Important: Do not apply force to the sensor (1) or the bearing adapter (3) in a sideways direction. 2. Install the sensor onto the steering shaft (2) and into the bearing adapter (3). Important: If installing a new sensor the sensor will come precentered. Do not remove the pin until installation is complete. 3. The sensor must be set to approximately 3 mm gap between the sensor and the bearing adapter. 4. Install the sensor connector. 5. Remove the pin from the sensor. 6. Install the sensor retainer onto the steering shaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2579 7. Install the steering column to the vehicle. 8. Remove J 42640 from the steering column. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2580 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Verify the type of steering wheel position sensor. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Remove the connector from the sensor. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Make an alignment mark on the flush rotor flange cuff (3). Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2581 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2582 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin-Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Important: If reusing the existing sensor, no centering of the sensor is required. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin-Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2583 ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin-Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin- Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2584 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin-Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin-Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2585 24. Install the connector to the sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations Ride Height Sensor: Locations Selectable Ride Switch Shock Absorber Solenoid Valves - LF, RF Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 2590 Shock Absorber Solenoid Valves - LR, RR Suspension Controls Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Lock the steering column through the access hole in the lower trim cover using J 42640. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 3. Remove the steering column from the vehicle. Important: A new sensor must come with a pin installed. If pin is not installed, return and reorder sensor. Do not apply force to the sensor and the bearing assembly in a sideways direction. 4. Remove the sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 5. Remove the sensor retainer from the steering shaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2596 6. Pin diameter must be in the range of 1-2 mm. Important: When reusing the sensor (1) you must install a pin into the sensor before it is removed from the steering shaft. By not installing a pin into the sensor it will cause the sensor to lose its centering position and must be discarded. Do not remove the bearing adapter (3). If reusing the sensor (1), remove the position sensor by pulling the sensor straight out from the bearing adapter (3) until the sensor is almost off the steering shaft (2). Install a pin into the sensor before removing from the steering shaft (2). Do not remove the pin until the sensor is re-installed. 7. If replacing the sensor (1), remove the sensor by pulling the sensor straight out from the bearing adapter (3) and off the steering shaft. Installation Procedure 1. If reusing the sensor, with the pin still installed, align the sensor onto the steering shaft (2) and into the bearing adapter (3). Important: Do not apply force to the sensor (1) or the bearing adapter (3) in a sideways direction. 2. Install the sensor onto the steering shaft (2) and into the bearing adapter (3). Important: If installing a new sensor the sensor will come precentered. Do not remove the pin until installation is complete. 3. The sensor must be set to approximately 3 mm gap between the sensor and the bearing adapter. 4. Install the sensor connector. 5. Remove the pin from the sensor. 6. Install the sensor retainer onto the steering shaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2597 7. Install the steering column to the vehicle. 8. Remove J 42640 from the steering column. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2598 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Verify the type of steering wheel position sensor. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Remove the connector from the sensor. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Make an alignment mark on the flush rotor flange cuff (3). Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2599 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2600 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin-Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Important: If reusing the existing sensor, no centering of the sensor is required. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin-Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2601 ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin-Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin- Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2602 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin-Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin-Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2603 24. Install the connector to the sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2612 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2613 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2614 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2615 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2616 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2617 Tire Pressure Sensor: Description and Operation Tire Pressure Monitor Description and Operation The Tire Pressure Monitor (TPM) system warns the driver when a significant loss of tire pressure occurs in any of the 4 tires, and (w/UK3) allows the driver to display the individual tire pressures, and their locations on the driver information center (DIC). The system uses the powertrain control module (PCM), body control module (BCM), instrument panel cluster (IPC), DIC, passenger door module (PDM) (w/YE9/5B5), remote control door lock receiver (RCDLR) (w/o YE9/5B5), a radio frequency (RF) transmitting pressure sensor in each wheel/tire assembly, and the serial data circuit to preform the system functions. When the vehicle is stationary and the sensor internal roll switches are open for at least 30 seconds, the sensors go into stationary mode. In this mode, the sensors sample tire pressure once every 20 seconds and transmit a stationary mode transmission once every 60 minutes. As vehicle speed increases, centrifugal force closes the sensor internal roll switch causing the sensors to go into drive mode. In this mode, the sensors sample tire pressure once every 30 seconds and transmit a drive mode transmission once every 60 seconds. The PDM/RCDLR receives and translates the data contained in each sensor RF transmission into sensor presence, sensor mode, and tire pressure. The PDM (w/UK3) then sends the tire pressure and tire location data to the DIC via the serial data circuit, where they are displayed as follows: ^ LF TIRE XX PSI ^ RF TIRE XX PSI ^ RR TIRE XX PSI ^ LR TIRE XX PSI The sensors continuously compare their current pressure sample with their last pressure sample and will transmit in re-measure mode whenever a 1.6 psi change in tire pressure has occurred. When the TPM system detects a significant loss of tire pressure, the CHECK TIRE PRESSURE message is displayed on the DIC and the low tire pressure indicator is displayed on the IPC. Both the DIC message and IPC indicator can be cleared by adjusting the tire pressure to the recommended kPa/psi. Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. The sensor pressure range is 0 - 703 kPa (0 - 102 psi). The sensor pressure accuracy from -10 to +70°C (+14 to +158°F) is plus or minus 14 kPa (2 psi). The PDM/RCDLR has the ability to detect malfunctions within the TPM system. Any malfunction detected will cause the DIC to display the SERVICE TIRE MONITOR message. For more information on other functions of the PDM/RCDLR, refer to the following: ^ Keyless Entry System Description and Operation ^ Power Door Locks Description and Operation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Grommet Replacement Tire Pressure Sensor Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire/wheel assembly from the vehicle. 3. Remove the tire from the wheel. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: ^ Place the sensors cap and valve on a dry clean surface after removal, the cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. ^ Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. ^ Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. ^ Repeat items for inner bead. 4. Remove the tire pressure sensor nut. Important: If any tire sealant is noted upon tire dismounting, replace the sensor. Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. ^ Tighten the sensor nut to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 2620 5. Install the tire on the wheel. Important: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: ^ Position the mounting/dismounting head 180 degrees from the valve stem. ^ Position the bead transition area 45 degrees counterclockwise of the valve stem. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. ^ Repeat items for outer bead. 6. Install the tire/wheel assembly on the vehicle. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 2621 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Replacement Tire Pressure Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire/wheel assembly from the vehicle. 3. Remove the tire from the wheel. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. ^ Place the sensors cap and valve on a dry clean surface after removal, the cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. ^ When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. ^ Position the mounting/dismounting head so the tire iron, or pry bar can be Inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. ^ Repeat items for inner bead. 4. Remove the tire pressure sensor nut. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. ^ Tighten the sensor nut to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the tire on the wheel. Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 2622 ^ Position the mounting/dismounting head 180 degrees from the valve stem. ^ Position the bead transition area 45 degrees counter clockwise of the valve stem. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. ^ Repeat items for outer bead. 5. Install the tire/wheel assembly on the vehicle. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor's unique identification code cannot be learned into the passenger door modules (PDMs) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 6. Lower the vehicle. 7. Learn the tire pressure sensors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 2623 Tire Pressure Sensor: Tools and Equipment Special Tools Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2630 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission Fluid Pressure Sensor/Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2633 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2634 Fluid Pressure Sensor/Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2637 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2638 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Remove the remaining valve body bolts. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2639 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2640 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2641 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2642 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2643 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2644 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2645 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2646 Fluid Pressure Sensor/Switch: Service and Repair 4L80-E/4L85-E - Automatic Transmission Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel(r) Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body: ^ The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2647 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2648 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Remove the 8 checkballs (9 for some models). Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2649 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Install the manual 2-1 band servo piston (1). Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2650 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2651 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2652 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2653 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Tow/Haul Switch: Locations Automatic Transmission Electronic Component Views Transmission Control Module (MW7) Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Engine Harness to Transmission Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 2657 Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Tow/Haul Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2660 Tow/Haul Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2661 Tow/Haul Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Transmission Internal Mode Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > Page 2662 Tow/Haul Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2666 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2667 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2670 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2673 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2676 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2677 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2678 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2679 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2680 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2681 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2686 Transmission Speed Sensor: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Vehicle Speed Sensor Assembly, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2689 Transmission Speed Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2690 Automatic Transmission Output Speed Sensor (OSS) Automatic Transmission Output Speed Sensor (OSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2691 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 2692 Automatic Transmission Turbine Speed Sensor Automatic Transmission Turbine Speed Sensor Vehicle Speed Sensor (VSS) Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2695 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2696 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2697 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2698 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2699 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2700 Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure 1. Be sure the vehicle ignition is turned off. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2701 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Install the speed sensor bolt (1). ^ Tighten bolt to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2706 Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2707 Transmission Temperature Sensor/Switch: Specifications Allison - Automatic Transmission Temperature vs Resistance (Transmission Fluid Temperature Sensor) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2708 Temperature vs Resistance (Speed Sensor) Temperature vs Resistance (Solenoid) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 2709 Transmission Temperature Sensor/Switch: Locations Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 2710 Transmission Temperature Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Transmission Fluid Temperature (TFT) Sensor, Wiring Harness Side Transmission Fluid Temperature (TFT) Sensor, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission Transmission Speed Sensor: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 2716 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 2717 Transmission Speed Sensor: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 2718 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 2719 Transmission Speed Sensor: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 2720 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Manual Transmission Transmission Speed Sensor: Service and Repair NV 3500 - Manual Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Manual Transmission > Page 2723 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Manual Transmission > Page 2724 Transmission Speed Sensor: Service and Repair NV 4500 - Manual Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Manual Transmission > Page 2725 3. Connect the VSS electrical connector (3). Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Manual Transmission > Page 2726 Transmission Speed Sensor: Service and Repair ZF S6-650 - Manual Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Manual Transmission > Page 2727 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Window Switch - LR (Crew Cab Only) Window Switch - RR (Crew Cab Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side > Page 2734 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side > Page 2735 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the screw (2) that retains the switch panel bezel (1) to the front door trim panel. 3. Remove the switch panel bezel from the door panel using a flat-bladed tool. 4. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 5. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side > Page 2736 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module into the door trim panel. 3. Install the screw (2) that retains the switch panel bezel (1) to the front door trim panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw (2) to 2 N.m (18 lb in). 4. Install the front door trim panel. 5. Perform the necessary setup and programming procedures. Refer to Door Control Module Programming and Setup in Vehicle Control Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side > Page 2737 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Windshield Washer Reservoir Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2742 Washer Fluid Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2748 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2749 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2750 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2751 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2752 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2753 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2754 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 2757 Trim Height Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 2758 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 2759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2760 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2761 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2762 If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Important: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2765 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications . When the caster and camber are within specifications, adjust the toe. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2766 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Front Caster and Camber Adjustment 1. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. Important: Caster measurements or values must be compensated for the measured frame angle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2767 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2768 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2769 Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2770 Alignment: Service and Repair Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Tighten the jam nut on the tie rod. Tighten the tie rod jam to 65 Nm (48 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster and Camber Adjustment > Page 2771 Alignment: Service and Repair Steering Wheel Angle and/or Front Toe Adjustment Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Tighten the jam nut on the tie rod. Tighten the tie rod jam to 68 Nm (50 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2778 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2779 Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2780 Step 6 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2796 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2802 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2808 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2809 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2810 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2811 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2817 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2818 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2819 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2820 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2821 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2822 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 2828 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1000 Ohms per ft Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2832 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2833 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(r) spark plug wires MUST be used only with the Melco(r) coils and bracket, like wise the Delphi(r) spark plug wires MUST be used only with Delphi(r) coils and bracket. The components are NOT interchangeable. 4. The Melco(r) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(r) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(r) (1) ignition coil is a square design. 7. The Delphi(r) (2) ignition coil is a round design. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2834 8. The Melco(r) ignition coil bracket (1) is a square design. 9. The Delphi(r) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................................... 1.52 mm (0.060 in.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2839 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ................................................... 15 Nm (11.0 lb. ft.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2840 Spark Plug: Application and ID SPARK PLUG TYPE AC Delco P/N ...................................................................................................................................... .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2841 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). An excessively wide electrode gap can prevent correct spark plug Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2842 operation. - Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2843 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2844 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder should read less than ............................................................................................................................................................ 690 kPa (100 psi). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2848 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 5 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2856 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2857 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2858 Drive Belt: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2859 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components ^ The power steering pump, if belt driven ^ The generator ^ The A/C compressor, if equipped ^ The engine cooling fan, if belt driven ^ The water pump, if belt driven ^ The vacuum pump, if equipped ^ The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2862 Step 1 - Step 14 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2863 Step 15 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2864 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Step 1 - Step 6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2865 Drive Belt: Testing and Inspection Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2866 Step 1 - Step 12 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2867 Drive Belt: Testing and Inspection Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Step 1 - Step 8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2868 Drive Belt: Testing and Inspection Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2869 Step 1 - Step 14 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2870 Step 15 Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Step 1 - Step 6 Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2871 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Step 1 - Step 12 Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2872 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Step 1 - Step 8 Drive Belt Squeal Diagnosis Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2873 proceed further in this table 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Step 1 - Step 9 Drive Belt Vibration Diagnosis Drive Belt Vibration Diagnosis Diagnostic Aids Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2874 The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2875 Step 1 - Step 11 Drive Belt Whine Diagnosis Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 2876 removal and installation procedure. Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement Drive Belt: Service and Repair Drive Belt Replacement Drive Belt Replacement - Accessory Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The mass airflow/intake air temperature (MAF/IAT) sensor 2. Disconnect the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 6. Remove the belt from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2879 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2880 9. Install the air cleaner outlet duct. 10. Connect the radiator inlet hose clip to the outlet duct. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 11. Tighten the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The MAF/IAT sensor Tighten Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2881 Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement Air Conditioning Compressor Belt Replacement Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2882 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening. 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Install the engine shield bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2883 12. Install the accessory drive belt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 2897 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2903 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2904 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2905 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle does not have a factory installed cabin filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2917 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2918 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2919 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2920 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2926 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2927 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2928 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2929 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2934 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2935 4. Install the oil pan and NEW gasket. 5. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2936 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2937 14. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. Important: It is not necessary to remove the selector cable from the bracket. 15. Remove the oil pan bolts. 16. Remove the oil pan and gasket. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2938 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.) 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.) 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2939 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2940 Fluid Filter - A/T: Service and Repair Allison - Automatic Transmission Transmission Fluid Filter Adapter Replacement Transmission Fluid Filter Adapter Replacement Removal Procedure 1. Remove the transmission external oil filter (4) by rotating in the counterclockwise direction. Important: ^ DO NOT drain the fluid if only the transmission external oil filter adapter is being replaced. ^ Use a standard strap-type filter wrench to remove or install the transmission external oil filter. 2. Remove the magnet (2) from the transmission external oil filter adapter (1) in the converter housing or from the filter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 4. Remove the filter adapter (1) from the converter housing. Installation Procedure 1. Install the transmission external oil filter adapter (1). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the adapter to 30 Nm (22 ft. lbs.). 2. Reinstall the magnet (2) onto the filter adapter (1). 3. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 4. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. Turn the filter ONE FULL TURN ONLY after gasket contact. 5. Check the transmission fluid level. 6. Notice: Use only clean and approved transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2941 Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 2. Inspect the drained fluid. 3. Remove the filter (4) by rotating in the counterclockwise direction. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Install the drain plug (6) and drain plug seal (5). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Refill Transmission with DEXRON(r)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. 7. Cycle the ignition until Drive or Reverse range is attained. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2942 Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. 8. Check the transmission fluid level. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 2948 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System Fuel Pump Pickup Filter: Description and Operation Fuel System FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System > Page 2953 Fuel Pump Pickup Filter: Description and Operation Fuel System (Cab Chassis) FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2958 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2959 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp from the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 2964 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the inlet heater hose from the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2969 6. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2970 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2971 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: Customer Interest A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel > Page 2980 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: All Technical Service Bulletins A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel > Page 2986 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement DISCHARGE HOSE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2989 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. 3. Install the discharge hose to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the discharge hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2990 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2991 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement EVAPORATOR TUBE REPLACEMENT (W/O HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the right park/turn signal lamp. 5. Remove the grille from the vehicle. 6. Remove the evaporator tube nut from the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the evaporator tube from the vehicle. 9. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2992 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2993 Hose/Line HVAC: Service and Repair Suction Hose Replacement (W/ Denso) SUCTION HOSE REPLACEMENT (W/DENSO) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the suction hose mounting bolt from the A/C compressor. 3. Remove the suction hose (2) from the A/C compressor. 4. Remove the suction hose nut from the accumulator. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose assembly from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE 1. Install the suction hose to the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2994 2. Install the suction hose to the accumulator using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 4. Install the suction hose (2) to the compressor using new sealing washers. 5. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3003 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3004 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3005 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3006 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3007 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3008 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3009 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3010 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3011 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3012 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3013 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3014 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3015 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3016 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > NHTSA05V455000 > Oct > 05 > Recall 05V455000: Power Steering Hose Fracturing Power Steering Line/Hose: Recalls Recall 05V455000: Power Steering Hose Fracturing MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2006 Cadillac/Escalade 2006 Chevrolet/Corvette 2005-2006 Chevrolet/Express 2006 Chevrolet/Silverado 2005-2006 Chevrolet/Tahoe 2006 Chevrolet/Trailblazer 2006 Chevrolet/Trailblazer EXT 2006 GMC/Envoy 2006 GMC/Envoy XL 2006 GMC/Savana 2006 GMC/Sierra 2005-2006 GMC/Yukon 2006 Hummer/H2 2006 Isuzu/Ascender 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V455000 MFG'S REPORT DATE: October 04, 2005 COMPONENT: Steering: Hydraulic Power Assist: Hose, Piping, and Connections POTENTIAL NUMBER OF UNITS AFFECTED: 123592 SUMMARY: Certain passenger vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. CONSEQUENCE: If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with Hydro-Boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. REMEDY: Dealers will inspect the power steering hose(s) for two suspect date codes and replace them if required. The recall will begin on October 14, 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Buick at 1-866-608-8080, Cadillac at 1-866-982-2339, Isuzu at 1-800-255-6727, or HUMMER at 1-800-732-5493. NOTES: GM recall No. 05086. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3026 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3027 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3028 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3029 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3030 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3031 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3032 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3033 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3034 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3035 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3036 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3037 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3038 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 3039 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > NHTSA05V455000 > Oct > 05 > Recall 05V455000: Power Steering Hose Fracturing Power Steering Line/Hose: All Technical Service Bulletins Recall 05V455000: Power Steering Hose Fracturing MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2006 Cadillac/Escalade 2006 Chevrolet/Corvette 2005-2006 Chevrolet/Express 2006 Chevrolet/Silverado 2005-2006 Chevrolet/Tahoe 2006 Chevrolet/Trailblazer 2006 Chevrolet/Trailblazer EXT 2006 GMC/Envoy 2006 GMC/Envoy XL 2006 GMC/Savana 2006 GMC/Sierra 2005-2006 GMC/Yukon 2006 Hummer/H2 2006 Isuzu/Ascender 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V455000 MFG'S REPORT DATE: October 04, 2005 COMPONENT: Steering: Hydraulic Power Assist: Hose, Piping, and Connections POTENTIAL NUMBER OF UNITS AFFECTED: 123592 SUMMARY: Certain passenger vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. CONSEQUENCE: If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with Hydro-Boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. REMEDY: Dealers will inspect the power steering hose(s) for two suspect date codes and replace them if required. The recall will begin on October 14, 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Buick at 1-866-608-8080, Cadillac at 1-866-982-2339, Isuzu at 1-800-255-6727, or HUMMER at 1-800-732-5493. NOTES: GM recall No. 05086. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. 2. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3046 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3047 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. 2. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3048 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3049 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Removal Procedure 1. Remove the front grille. 2. Remove the power steering outlet hose (4) from the power steering gear (3). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering inlet hose from the power steering pump (1). 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3050 2. Connect the power steering inlet hose to the power steering pump (5). Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3). Install the retaining clamp. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3051 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 3. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3052 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. 9. Connect the energy storage box after servicing the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3053 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. 2. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3054 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. 2. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3055 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Removal Procedure 1. Remove the front grille. 2. Remove the power steering outlet hose (4) from the power steering gear (3). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering inlet hose from the power steering pump (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3056 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering inlet hose to the power steering pump (5). Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3). Install the retaining clamp. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3057 3. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3058 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. 9. Connect the energy storage box after servicing the vehicle. Power Steering Hose Assembly Replacement (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3059 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3060 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3061 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. 9. Connect the energy storage box after servicing the vehicle. Power Steering Hose Assembly Replacement (Rack and Pinion Power Steering Hose Assembly Replacement (Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3062 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3063 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3064 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. 9. Connect the energy storage box before after servicing the vehicle. Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3065 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting 2. Remove the engine protection shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3066 3. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3067 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.) Notice: Refer to Fastener Notice in Service Precautions. 3. Bleed the power steering system. 4. Inspect all the hose connections for leaks. Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1). Remove the power steering gear outlet hose from the power steering pump. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3068 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the power steering gear outlet hose (3) to the power steering pump (1). Position the clamp at the end of the hose. 3. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3069 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3070 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3071 1. Route the hose in the same position the hose occupied prior to removal. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 2. Install the brake booster outlet hose (1) to the brake booster (2). Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4). Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3072 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3073 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3074 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box after servicing the vehicle. (Rack and Pinion) Power Steering Hose Assembly Replacement (Rack and Pinion) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3075 Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3076 Installation Procedure 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 3077 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box before after servicing the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Hose Replacement - Inlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet hose. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator inlet hose clips. 7. Reposition the inlet hose clamp at the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Remove the inlet hose (1) from the radiator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3082 10. Reposition the inlet hose clamp at the water pump. 11. Remove the inlet hose from the water pump. Installation Procedure 1. Install the inlet hose to the water pump. 2. Position the inlet hose clamp at the water pump. 3. Install the inlet hose (1) to the radiator. 4. Position the inlet hose clamp at the radiator. 5. Install the inlet hose clip to the fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3083 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield. 8. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. 10. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor ^ Tighten the clamps to 4 Nm (35 inch lbs.). 11. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3084 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the outlet hose clamp at the water pump. 6. Remove the outlet hose from the water pump. 7. Reposition the outlet hose clamp at the radiator. 8. Remove the outlet hose (6) from the radiator. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3085 1. Install the outlet hose (6) to the radiator. 2. Position the outlet hose clamp at the radiator. 3. Install the outlet hose to the water pump. 4. Position the outlet hose clamp at the water pump. 5. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor ^ Tighten the clamps to 4 Nm (35 inch lbs.). 8. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not provided by manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 3091 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Information not provided by the manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 3096 Clutch Fluid: Fluid Type Specifications HYDRAULIC CLUTCH SYSTEM (5-SPEED TRANS.) Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. HYDRAULIC CLUTCH SYSTEM (6-SPEED TRANS.) Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, Super DOT-4 brake fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3101 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3102 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3103 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3104 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY AUTOMATIC WITH FRONT A/C With Engine Fan Driven cooling system ..................................................................................................................................... 15.2 quarts (14.4 liters) With Electric Cooling Fan system .............................................................................................................................................. 16.8 quarts (15.9 liters) MANUAL WITH FRONT A/C With Engine Fan Driven cooling system ..................................................................................................................................... 15.5 quarts (14.7 liters) With Electric Cooling Fan system .............................................................................................................................................. 17.0 quarts (16.1 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 3107 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3112 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3113 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3114 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E/4L65-E/4L70-E Pan Removal ................................................................................................. .................................................................................................... 4.7L (5.0 Qt) Overhaul .................... .............................................................................................................................................................. ...................... 10.6L (11.0 Qt) 4L80-E/4L85-E Dry .............................................................................................................................. .................................................................................. 12.8L (13.5 Qt) Pan Removal ........................... .............................................................................................................................................................. ............ 7.3L (7.7 Qt) Allison Overhaul .................................................................................................................................. ...................................................................... 12.0L (12.7 Qt) Fluid Change ....................................... .............................................................................................................................................................. 7.0L (7.4 Qt) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3117 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure Fluid - A/T: Testing and Inspection Allison Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Cold Fluid Check The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. 1. Bring the vehicle to a complete stop on a level surface using the service brakes. Important: The fluid level rises as fluid temperature increases. DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 2. Ensure that the engine is at low idle RPM (500-800 RPM). 3. With the service brakes applied, put the transmission in the P, PARK, position. 4. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 5. Apply the parking brake and ensure it is properly engaged. 6. Run the engine for at least one minute. Apply the service brakes and shift to D, DRIVE, then to N, NEUTRAL, and then shift to R, REVERSE, in order to fill the hydraulic system. 7. Ensure that the engine is at low idle RPM (500-800 RPM). 8. With the service brakes applied, put the transmission in the P, PARK, position. 9. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 10. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 11. Insert the fluid level indicator into the fill tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. Important: ^ If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD CHECK band, add or drain as necessary to bring it to the middle of the COLD CHECK band. ^ Always check the fluid level at least twice using the procedure described above. Consistent readings are important in order to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure that it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 12. Perform a hot check at the first opportunity after the normal operating sump temperature of 71 93°C (160 - 200°F) is reached. Hot Fluid Check 1. Operate the transmission in D, DRIVE, range until normal operating temperature is reached. Normal operating temperature is any of the following: ^ Sump temperature 71 - 93°C (160 - 200°F) ^ Converter-out temperature 82 - 104°C (180 - 220°F) ^ If a transmission temperature gage is not present, check the fluid level when the engine water temperature gage has stabilized and the transmission has been operated under load for at least one hour. Important: The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases. 2. Bring the vehicle to a complete stop on a level surface using the service brake. 3. Ensure that the engine is at low idle RPM, 500-800 RPM. 4. With the service brakes applied, place the transmission in the P, PARK, position. 5. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 6. Apply the parking brake and ensure it is properly engaged. 7. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 8. Insert the fluid level indicator into fill the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading. Important: Always check the fluid level at least twice using the procedure described above. Consistent readings are important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 9. If the fluid level is not within the HOT RUN band, add or drain as necessary to bring the fluid level to within the HOT RUN band. Important: Safe operating level is within the HOT RUN band on the fluid level indicator. The width of the HOT RUN band represents approximately 1.0 liter (1.06 quarts) of fluid at normal operating sump temperature. Fluid Inspection Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 3120 1. Examine the drained fluid for evidence of dirt. Important: Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. High temperature causes the transmission fluid to be discolored or to have a strong odor. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. 2. Examine the drained fluid for evidence of water. Obvious water contamination of the transmission fluid or transmission fluid in the cooling water from the heat exchanger indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. Important: Cooler water may be contaminated by engine oil if an engine oil cooler is present; be sure to locate the correct source of cooler water contamination. 3. Examine the drained fluid for evidence of engine coolant. Notice: Engine coolant in the transmission hydraulic system requires immediate action. Failure to clean or replace all contaminated components may result in premature transmission failure. 4. Examine the drained fluid for evidence of metal. Metal particles in the fluid, other than minute particles normally trapped in the oil filter, indicate internal transmission damage. When this occurs, inspect the inside of the oil pan for excessive metal particles. 5. Metal contamination requires complete transmission disassembly. 6. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. Notice: Flush the transmission cooling system and inspect for restrictions following a transmission failure. Failure to repair or replace restricted oil cooling system components may result in premature transmission failure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 3121 Fluid - A/T: Testing and Inspection 4L60-E/4L65-E/4L70-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 3122 Step 1 - Step 17 Step 18 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 3123 Fluid - A/T: Testing and Inspection 4L80-E/4L85-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 3124 Step 1 - Step 15 Step 16 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3127 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3128 4. Install the oil pan and NEW gasket. 5. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3129 Step 1 - Step 17 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3130 Step 18 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3131 Fluid - A/T: Service and Repair 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3132 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). 14. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. Important: It is not necessary to remove the selector cable from the bracket. 15. Remove the oil pan bolts. 16. Remove the oil pan and gasket. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 17. Remove the magnet from the bottom of the pan, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3133 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3134 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3135 Step 1 - Step 15 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3136 Step 16 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3137 Fluid - A/T: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 2. Inspect the drained fluid. 3. Remove the filter (4) by rotating in the counterclockwise direction. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Install the drain plug (6) and drain plug seal (5). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3138 6. Refill Transmission with DEXRON(r)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. 7. Cycle the ignition until Drive or Reverse range is attained. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. 8. Check the transmission fluid level. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Cold Fluid Check The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. 1. Bring the vehicle to a complete stop on a level surface using the service brakes. Important: The fluid level rises as fluid temperature increases. DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 2. Ensure that the engine is at low idle RPM (500-800 RPM). 3. With the service brakes applied, put the transmission in the P, PARK, position. 4. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 5. Apply the parking brake and ensure it is properly engaged. 6. Run the engine for at least one minute. Apply the service brakes and shift to D, DRIVE, then to N, NEUTRAL, and then shift to R, REVERSE, in order to fill the hydraulic system. 7. Ensure that the engine is at low idle RPM (500-800 RPM). 8. With the service brakes applied, put the transmission in the P, PARK, position. 9. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 10. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 11. Insert the fluid level indicator into the fill tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. Important: ^ If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD CHECK band, add or drain as necessary to bring it to the middle of the COLD CHECK band. ^ Always check the fluid level at least twice using the procedure described above. Consistent readings are important in order to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure that it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 12. Perform a hot check at the first opportunity after the normal operating sump temperature of 71 93°C (160 - 200°F) is reached. Hot Fluid Check 1. Operate the transmission in D, DRIVE, range until normal operating temperature is reached. Normal operating temperature is any of the following: ^ Sump temperature 71 - 93°C (160 - 200°F) ^ Converter-out temperature 82 - 104°C (180 - 220°F) ^ If a transmission temperature gage is not present, check the fluid level when the engine water temperature gage has stabilized and the transmission has been operated under load for at least one hour. Important: The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases. 2. Bring the vehicle to a complete stop on a level surface using the service brake. 3. Ensure that the engine is at low idle RPM, 500-800 RPM. 4. With the service brakes applied, place the transmission in the P, PARK, position. 5. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 6. Apply the parking brake and ensure it is properly engaged. 7. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 8. Insert the fluid level indicator into fill the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3139 Important: Always check the fluid level at least twice using the procedure described above. Consistent readings are important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 9. If the fluid level is not within the HOT RUN band, add or drain as necessary to bring the fluid level to within the HOT RUN band. Important: Safe operating level is within the HOT RUN band on the fluid level indicator. The width of the HOT RUN band represents approximately 1.0 liter (1.06 quarts) of fluid at normal operating sump temperature. Fluid Inspection 1. Examine the drained fluid for evidence of dirt. Important: Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. High temperature causes the transmission fluid to be discolored or to have a strong odor. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. 2. Examine the drained fluid for evidence of water. Obvious water contamination of the transmission fluid or transmission fluid in the cooling water from the heat exchanger indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. Important: Cooler water may be contaminated by engine oil if an engine oil cooler is present; be sure to locate the correct source of cooler water contamination. 3. Examine the drained fluid for evidence of engine coolant. Notice: Engine coolant in the transmission hydraulic system requires immediate action. Failure to clean or replace all contaminated components may result in premature transmission failure. 4. Examine the drained fluid for evidence of metal. Metal particles in the fluid, other than minute particles normally trapped in the oil filter, indicate internal transmission damage. When this occurs, inspect the inside of the oil pan for excessive metal particles. 5. Metal contamination requires complete transmission disassembly. 6. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. Notice: Flush the transmission cooling system and inspect for restrictions following a transmission failure. Failure to repair or replace restricted oil cooling system components may result in premature transmission failure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transaxle Fluid 2WD ..................................................................................................................................................... ................................................. 2.5 quarts (2.3 liters) 4WD ..................................................................................................................................................... ................................................. 2.2 quarts (2.0 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3144 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION (5-SPEED WITH LOW GEAR, RPO MW3) GM Goodwrench Synthetic Manual Transmission Fluid (GM Part No. U.S. 12346190, in Canada 10953477) or equivalent SAE 75W-85 GL-4 gear oil. MANUAL TRANSMISSION (5-SPEED WITHOUT LOW GEAR, RPO MG5) Synchromesh Transmission Fluid (GM Part No. U.S. 12345349, in Canada 10953465). MANUAL TRANSMISSION (6-SPEED) Synthetic Transmission Fluid approved to Allison Transmission specification TES-295 (GM Part No. U.S. 12378515, in Canada 88900701). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission Fluid - M/T: Service and Repair NV 3500 - Manual Transmission Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 3147 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 3148 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 3149 Fluid - M/T: Service and Repair NV 4500 - Manual Transmission Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 3150 3. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications. 4. Install the oil fill plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 3151 Fluid - M/T: Service and Repair ZF S6-650 - Manual Transmission Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DRIVE AXLE CAPACITIES Front Drive Axle (8.25") .......................................................................... ......................................................................................... 1.43 liters (1.51 quarts) Front Drive Axle (9.25") .................................................................................................................................................. ................. 1.73 liters (1.83 quarts) Rear Drive Axle (8.6") .................................................................. .................................................................................................... 2.03 liters (2.15 quarts) Rear Drive Axle (9.5") ............................................................................................................................................ ............................ 2.6 liters (2.75 quarts) Rear Drive Axle (9.75") ....................................................... ............................................................................................................. 2.84 liters (3.00 quarts) Rear Drive Axle (10.5") ................................................................................................................................ ...................................... 2.6 liters (2.75 quarts) Rear Drive Axle (11.5") ............................................. ......................................................................................................................... 3.0 liters (3.17 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3156 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 1052271, in Canada 10950849). FRONT AXLE (1500 HD, 2500, 2500 HD, AND 3500 SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 12378261, in Canada 10953455) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 12378261, in Canada 10953455) meeting GM Specification 9986115. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15 - 40 mm (0.6 - 1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15 40 mm (0.6 - 1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. 10. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3159 Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. 8. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3160 Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3161 Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle (9.5 Inch HD and 10.5 Inch Axles) Lubricant Level Inspection - Rear Drive Axle (9.5 Inch HD and 10.5 Inch Axles) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice. 9. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3162 Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15 - 40 mm (0.6 - 1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15 40 mm (0.6 - 1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. 10. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 11. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3163 8. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.5 Inch HD and 10.5 Inch Axles) Lubricant Level Inspection - Rear Drive Axle (9.5 Inch HD and 10.5 Inch Axles) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3164 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 4 mm (0 - 0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.5 LD Axle) Lubricant Level Inspection - Rear Drive Axle (9.5 LD Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3165 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice. 9. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure 1. Install a new gasket and the rear axle housing cover (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3166 2. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the rear axle housing cover bolts. 3. Fill the rear axle. Use the proper fluid. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.5 inch HD and 10.5 Inch Axles) Lubricant Replacement - Rear Drive Axle (9.5 inch HD and 10.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. For the 9.5/9.5LD and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3167 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice. 2. Fill the rear axle. Use the proper fluid. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 3. For the 9.5/9.5LD and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3168 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3169 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). Notice: Refer to Service Precautions. 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.5 LD Axle) Lubricant Replacement - Rear Drive Axle (9.5 LD Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the rear axle fill plug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3170 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice. 2. Fill the rear axle. Use the proper fluid. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.5/9.5LD, 10.5, and 11.5 Inch Axles) Lubricant Replacement - Rear Drive Axle (9.5/9.5LD, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3171 2. For the 9.5/9.5LD and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) > Page 3172 Notice: Refer to Service Precautions. 2. Fill the rear axle. Use the proper fluid. 3. For the 9.5/9.5LD and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3177 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3178 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3181 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE Look for two things: 1.GM6094M Your vehicle's engine requires oil meeting GM Standard GM6094M. 2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container, and use only those oils that are identified as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3182 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3183 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Information not provided by manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 3188 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 3193 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 3194 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ...................................................... 1.6 lbs. (0.73 kg) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3197 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3198 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ACCUMULATOR REPLACEMENT NOTE: Add 60 ml (2 ounces) of PAG oil, plus the equal amount of oil drained from the accumulator. COMPRESSOR REPLACEMENT .................................................................................................................................................. 60 ml (2.0 ounces) NOTE:The Denso replacement compressor is precharged with 237 ml (8.0 ounces) of PAG oil. CONDENSER REPLACEMENT ..................................................................................................................................................... 30 ml (1.0 ounces) EVAPORATOR REPLACEMENT .................................................................................................................................................. 90 ml (3.0 ounces) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount drained. TOTAL SYSTEM PAG OIL CAPACITY ..................................................................................................................................... 210 ml (7.1 ounces) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 3205 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL Polyalkylene glycol (PAG) Oil ................................................................................................................ GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual). 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 3210 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder -after all air has been purged from the front port of the master cylinder -loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely -after all air has been purged from the right rear hydraulic circuit -install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely -after all air has been purged from the left rear hydraulic circuit -install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely -after all air has been purged from the right front hydraulic circuit -install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection . See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 3211 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 3212 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3217 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both front end sensor connectors (2) located on the frame crossmember (1). IMPORTANT: This vehicle is equipped with two inflatable restraint front end sensors. When performing this procedure be sure to include both front end sensors. 7. Disconnect both front end sensor connectors (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the front end sensor connectors (2) to both front end sensors. 3. Install the CPAs to both front end sensor connectors (2). 4. Install the SIR fuse into the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3218 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3219 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the I/P module yellow 4-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 4-way connector (1). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3220 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both front end sensor connectors (2) located on the frame crossmember (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3221 IMPORTANT: This vehicle is equipped with two inflatable restraint front end sensors. When performing this procedure be sure to include both front end sensors. 7. Disconnect both front end sensor connectors (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the front end sensor connectors (2) to both front end sensors. 3. Install the CPAs to both front end sensor connectors (2). 4. Install the SIR fuse into the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3222 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the I/P module yellow 4-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 4-way connector (1). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3223 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door (4). 7. Disconnect the side impact sensor yellow 2-way connector (5). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door (4). 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5). 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 7 SIR DISABLING AND ENABLING ZONE 7 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3224 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). 7. Remove the CPA from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 8. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Connect the I/P module yellow 4-way connector (1) located behind the I/P support. 5. Install the CPA to the I/P module yellow 4-way connector (1). 6. Install the SIR fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label Fuse: Locations Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3232 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3233 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3234 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3235 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3236 Fuse: Locations Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3237 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3238 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3239 Fuse: Locations Fuse Block - I/P Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3240 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3241 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3242 Fuse: Locations Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3243 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3244 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3245 Fuse: Locations Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3246 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3247 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3248 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3249 Location View Fuse Block - Underhood - Cooling Fan (10 Series) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3250 Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3251 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3252 Location View Fuse Block - I/P Label Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3253 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3254 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3255 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3256 Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3257 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3258 Location View Junction Block - I/P Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3259 Location View Junction Block - Rear Lamps Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Label > Page 3260 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 Fuse: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3298 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3299 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3300 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label Fuse: Application and ID Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3335 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3336 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3337 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3338 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3339 Fuse: Application and ID Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3340 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3341 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3342 Fuse: Application and ID Fuse Block - I/P Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3343 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3344 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3345 Fuse: Application and ID Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3346 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3347 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3348 Fuse: Application and ID Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3349 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3350 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3351 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3352 Location View Fuse Block - Underhood - Cooling Fan (10 Series) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3353 Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3354 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3355 Location View Fuse Block - I/P Label Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3356 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3357 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3358 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3359 Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3360 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3361 Location View Junction Block - I/P Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3362 Location View Junction Block - Rear Lamps Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3363 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3368 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3370 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3371 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 Fuse Block: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3404 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 Fuse Block: Connector Views Fuse Block - Underhood C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 Fuse Block - Underhood C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3440 Fuse Block - Underhood C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3441 Fuse Block - Underhood C2 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3442 Fuse Block - Underhood C2 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 Fuse Block - Underhood C2 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 Fuse Block - Underhood C3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 Fuse Block - Underhood C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 Fuse Block - Underhood C5 Fuse Block - Underhood C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 Fuse Block - Underhood C7 Fuse Block - Underhood C9 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 Fuse Block - Underhood - Cooling Fan (10 Series) Connector Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 Fuse Block - I/P C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 Fuse Block - I/P C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 Fuse Block - I/P C1 (Part 3) Fuse Block - I/P C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Fuse Block - I/P C3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Junction Block - I/P Wire Entry (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Junction Block - I/P Wire Entry (Part 2) Junction Block - I/P - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Junction Block - I/P - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Junction Block - I/P - C5 Junction Block - I/P - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Junction Block - I/P - C7 Junction Block - I/P - C8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3465 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3466 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3467 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3468 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3469 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3470 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 Relay Box: Diagrams Relay Block - I/P C1 Relay Block - I/P C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3475 Relay Block - I/P C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3476 Relay Block - I/P C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3477 Relay Block - I/P C3 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3478 Relay Block - I/P C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3479 Relay Block - I/P C5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3480 Relay Box: Diagrams Relay Block - I/P C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3481 Relay Block - I/P C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3482 Relay Block - I/P C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3483 Relay Block - I/P C3 Relay Block - I/P C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3484 Relay Block - I/P C5 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3485 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Relay Block - I/P C9 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3486 Relay Block - I/P C10 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3487 Junction Block - I/P Wire Entry (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3488 Junction Block - I/P Wire Entry (Part 2) Junction Block - I/P - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3489 Junction Block - I/P - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3490 Junction Block - I/P - C5 Junction Block - I/P - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3491 Junction Block - I/P - C7 Junction Block - I/P - C8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3492 Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3493 Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3494 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Block - I/P C1 > Page 3495 Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label Relay Box: Application and ID Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3498 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3499 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3500 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3501 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3502 Relay Box: Application and ID Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3503 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3504 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3505 Relay Box: Application and ID Fuse Block - I/P Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3506 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3507 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3508 Relay Box: Application and ID Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3509 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3510 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3511 Relay Box: Application and ID Fuse Block - Underhood Label Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3512 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3513 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3514 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3515 Location View Fuse Block - Underhood - Cooling Fan (10 Series) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3516 Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3517 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3518 Location View Fuse Block - I/P Label Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3519 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3520 Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3521 Location View Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3522 Relay Block - I/P Label Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3523 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3524 Location View Junction Block - I/P Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3525 Location View Junction Block - Rear Lamps Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Label > Page 3526 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3529 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3530 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3531 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3532 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3533 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Body Wiring Harness Junction Block Replacement > Page 3534 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3540 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3541 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3542 Customer TPMS Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3543 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3544 Frequently Asked Questions Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Page 3545 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE SENSOR LEARN (Vehicles with TPM) TOOLS REQUIRED J-46079 Tire Pressure Monitor Diagnostic Tool TPM LEARN MODE DESCRIPTION The Tire Pressure Monitor (TPM) system uses the passenger door module (PDM) (w/YE9/5B5), remote control door lock receiver (RCDLR) (w/o YE9/5B5), body control module (BCM), exterior lamp switch, 4 RF transmitting pressure sensors and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, PDM/RCDLR replacement, or sensor replacement. Once the TPM learn mode has been enabled, each of the sensor's unique identification (ID) codes can be learned in to the PDM/RCDLR memory. When a sensor ID has been learned, the PDM/RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the PDM/RCDLR has received and learned it. The PDM/RCDLR must learn the sensor IDs in the proper order to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. SENSOR FUNCTIONS USING PRESSURE INCREASE/DECREASE METHOD Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 1.6 psi from the last transmitted pressure, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in re-measure mode. When the PDM/RCDLR receives a re-measure mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. SENSOR FUNCTIONS USING J-46079 Each sensor has an internal low frequency (LF) coil. When the J-46079 is used in activate mode it produces an LF transmission that activates the sensor. The sensor responds to a LF activation by transmitting in learn mode. When the PDM/RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. TPM LEARN MODE CANCELLATION The learn mode will cancel if more than 2 minutes have passed and no sensor have been learned, or if more than 5 minutes has passed for the entire procedure. If the learn mode is canceled before any IDs are learned, the PDM/RCDLR will remember all previously stored IDs and their locations. As soon as the PDM/RCDLR learns the first ID, all other IDs are erased from the PDM/RCDLR memory. IMPORTANT: Before proceeding with the steps below, ensure that no other sensor learn procedure is being performed simultaneously, or that tire pressures are not being adjusted on a TPM equipped vehicle within close proximity. 1. Turn "ON" the ignition, with the engine "OFF". 2. Apply the parking brake. IMPORTANT: If the learn mode cannot be enabled, ensure the TPM system is enabled in the PDM/RCDLR. 3. Cycle the exterior lamp switch from "OFF" to parking lamps 4 times within 4 seconds. A double horn chirp will sound and the low tire pressure indicator will begin to flash indicating the learn mode has been enabled. CAUTION: Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. 4. Starting with the left front tire, hold the antenna of the J-46079 against the tire sidewall close to the wheel rim at the valve stem location then press and release the activate button and wait for a horn chirp, or increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before the 8-10 second pressure increase/decrease time period has been reached, or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. 5. After the horn chirp has sounded, proceed as in step 4 for the next 3 sensors in the following order: - Right front - Right rear - Left rear 6. After the LR sensor has been learned, turn OFF the ignition to exit the learn mode. 7. After the learn mode has been exited, adjust all tire pressures to the recommended psi. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light, (if equipped) will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL FUNCTION - The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION - The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Testing for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests and General Diagnostics TEST DESCRIPTION Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3554 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3555 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL FUNCTION - The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL ILLUMINATION - The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3556 Step 1 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3557 Step 14 - Step 16 The number below refers to the step number on the diagnostic table. 4. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil Life System When to Change Engine Oil Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL message will come on. See DIC Warnings and Messages . Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. Your dealer has GM-trained service people who will perform this work using genuine GM parts and reset the system. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change the oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System (Gasoline Engine) (From Owner's Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Any time the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change the oil prior to a CHANGE ENGINE OIL message being turned on, reset the system. To reset the Engine Oil Life System, do the following: 1. Turn the ignition key to RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. - If the OIL LIFE RESET message displays for 10 seconds, the system is resetting. 3. Turn the ignition key to LOCK. If the CHANGE ENGINE OIL message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. If it still does not reset, see your dealer for service. How to Reset the Engine Oil Life System (Diesel Engine) (From Owner's Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change the oil prior to a CHANGE ENGINE OIL message (pickup models) or a change engine oil light (van models) being turned on, reset the system. To reset the Engine Oil Life System: 1. Turn the ignition key to ON/ RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. - Pickup Models: If the OIL LIFE RESET message displays for 10 seconds, the system is resetting. - Van Models: If the change engine oil light flashes for five seconds, the system is reset. 3. Turn the ignition key to LOCK/OFF. If the message or light comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. If it still does not reset, see your dealer/retailer for service. GM Oil Life System Resetting (From Service Manual) When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come ON. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > Page 3561 How to Reset the Engine Oil Life System (From Service Manual) 1. Turn the ignition key to RUN with the engine OFF. 2. Fully press and release the accelerator pedal 3 times within 5 seconds. If the OIL LIFE RESET message flashes for 10 seconds, the system is resetting. 3. Turn the key to LOCK. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the ENGINE OIL LIFE SYSTEM has not reset. Repeat the procedure. What to Do with Used Oil Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of used oil, ask your dealer, a service station, or a local recycling center for help. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > General Information Vehicle Lifting: Service and Repair General Information LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > General Information > Page 3568 Vehicle Lifting: Service and Repair Frame Contact Lift FRAME CONTACT HOIST FRONT HOIST PADS IMPORTANT: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. REAR HOIST PADS IMPORTANT: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > General Information > Page 3569 Vehicle Lifting: Service and Repair Suspension Contact Lift SUSPENSION CONTACT HOIST FRONT LIFT Position the front lift under the outer edge of the front suspension lower control arms. REAR LIFT Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > General Information > Page 3570 Vehicle Lifting: Service and Repair Vehicle Jacking JACKING When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails IMPORTANT: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Page 3576 Tire Pressure Module: Service and Repair Control Module Setup Passenger Door Module (PDM) Setup After passenger door module (PDM) switch assembly replacement, the following procedures must be performed in the order that they appear for the Tire Pressure Monitor (TPM) System to function properly. The PDM also requires keyless entry transmitter programming after replacement. Refer to Transmitter Synchronization. TPM System Enable The service replacement PDM switch assembly comes with the TPM System disabled to allow the same part number PDM to be used in both TPM and non-TPM equipped vehicles. Once the TPM option is enabled in the PDM, it cannot be disabled. Before proceeding with the steps below, ensure the vehicle is equipped with TPM (UJ6). Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Chassis. 4. Select Tire Pressure Monitor. 5. Select Special Functions. 6. Select TPM Option Enable. 7. Press the exit key to escape. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Chassis. 4. Select Tire Pressure Monitor. 5. Select Special Functions. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle driver door placard sticker. 9. Select the rear tire pressure as noted on the vehicle driver door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After PDM switch assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the PDM memory. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3586 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3587 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3588 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3589 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3590 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 3591 Tire Pressure Sensor: Description and Operation Tire Pressure Monitor Description and Operation The Tire Pressure Monitor (TPM) system warns the driver when a significant loss of tire pressure occurs in any of the 4 tires, and (w/UK3) allows the driver to display the individual tire pressures, and their locations on the driver information center (DIC). The system uses the powertrain control module (PCM), body control module (BCM), instrument panel cluster (IPC), DIC, passenger door module (PDM) (w/YE9/5B5), remote control door lock receiver (RCDLR) (w/o YE9/5B5), a radio frequency (RF) transmitting pressure sensor in each wheel/tire assembly, and the serial data circuit to preform the system functions. When the vehicle is stationary and the sensor internal roll switches are open for at least 30 seconds, the sensors go into stationary mode. In this mode, the sensors sample tire pressure once every 20 seconds and transmit a stationary mode transmission once every 60 minutes. As vehicle speed increases, centrifugal force closes the sensor internal roll switch causing the sensors to go into drive mode. In this mode, the sensors sample tire pressure once every 30 seconds and transmit a drive mode transmission once every 60 seconds. The PDM/RCDLR receives and translates the data contained in each sensor RF transmission into sensor presence, sensor mode, and tire pressure. The PDM (w/UK3) then sends the tire pressure and tire location data to the DIC via the serial data circuit, where they are displayed as follows: ^ LF TIRE XX PSI ^ RF TIRE XX PSI ^ RR TIRE XX PSI ^ LR TIRE XX PSI The sensors continuously compare their current pressure sample with their last pressure sample and will transmit in re-measure mode whenever a 1.6 psi change in tire pressure has occurred. When the TPM system detects a significant loss of tire pressure, the CHECK TIRE PRESSURE message is displayed on the DIC and the low tire pressure indicator is displayed on the IPC. Both the DIC message and IPC indicator can be cleared by adjusting the tire pressure to the recommended kPa/psi. Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. The sensor pressure range is 0 - 703 kPa (0 - 102 psi). The sensor pressure accuracy from -10 to +70°C (+14 to +158°F) is plus or minus 14 kPa (2 psi). The PDM/RCDLR has the ability to detect malfunctions within the TPM system. Any malfunction detected will cause the DIC to display the SERVICE TIRE MONITOR message. For more information on other functions of the PDM/RCDLR, refer to the following: ^ Keyless Entry System Description and Operation ^ Power Door Locks Description and Operation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Grommet Replacement Tire Pressure Sensor Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire/wheel assembly from the vehicle. 3. Remove the tire from the wheel. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: ^ Place the sensors cap and valve on a dry clean surface after removal, the cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. ^ Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. ^ Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. ^ Repeat items for inner bead. 4. Remove the tire pressure sensor nut. Important: If any tire sealant is noted upon tire dismounting, replace the sensor. Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. ^ Tighten the sensor nut to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 3594 5. Install the tire on the wheel. Important: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: ^ Position the mounting/dismounting head 180 degrees from the valve stem. ^ Position the bead transition area 45 degrees counterclockwise of the valve stem. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. ^ Repeat items for outer bead. 6. Install the tire/wheel assembly on the vehicle. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 3595 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Replacement Tire Pressure Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire/wheel assembly from the vehicle. 3. Remove the tire from the wheel. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. ^ Place the sensors cap and valve on a dry clean surface after removal, the cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. ^ When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. ^ Position the mounting/dismounting head so the tire iron, or pry bar can be Inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. ^ Repeat items for inner bead. 4. Remove the tire pressure sensor nut. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. ^ Tighten the sensor nut to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the tire on the wheel. Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 3596 ^ Position the mounting/dismounting head 180 degrees from the valve stem. ^ Position the bead transition area 45 degrees counter clockwise of the valve stem. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. ^ Repeat items for outer bead. 5. Install the tire/wheel assembly on the vehicle. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor's unique identification code cannot be learned into the passenger door modules (PDMs) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 6. Lower the vehicle. 7. Learn the tire pressure sensors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 3597 Tire Pressure Sensor: Tools and Equipment Special Tools Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3603 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3604 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3605 Customer TPMS Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3606 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3607 Frequently Asked Questions Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Page 3608 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE SENSOR LEARN (Vehicles with TPM) TOOLS REQUIRED J-46079 Tire Pressure Monitor Diagnostic Tool TPM LEARN MODE DESCRIPTION The Tire Pressure Monitor (TPM) system uses the passenger door module (PDM) (w/YE9/5B5), remote control door lock receiver (RCDLR) (w/o YE9/5B5), body control module (BCM), exterior lamp switch, 4 RF transmitting pressure sensors and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, PDM/RCDLR replacement, or sensor replacement. Once the TPM learn mode has been enabled, each of the sensor's unique identification (ID) codes can be learned in to the PDM/RCDLR memory. When a sensor ID has been learned, the PDM/RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the PDM/RCDLR has received and learned it. The PDM/RCDLR must learn the sensor IDs in the proper order to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. SENSOR FUNCTIONS USING PRESSURE INCREASE/DECREASE METHOD Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 1.6 psi from the last transmitted pressure, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in re-measure mode. When the PDM/RCDLR receives a re-measure mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. SENSOR FUNCTIONS USING J-46079 Each sensor has an internal low frequency (LF) coil. When the J-46079 is used in activate mode it produces an LF transmission that activates the sensor. The sensor responds to a LF activation by transmitting in learn mode. When the PDM/RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. TPM LEARN MODE CANCELLATION The learn mode will cancel if more than 2 minutes have passed and no sensor have been learned, or if more than 5 minutes has passed for the entire procedure. If the learn mode is canceled before any IDs are learned, the PDM/RCDLR will remember all previously stored IDs and their locations. As soon as the PDM/RCDLR learns the first ID, all other IDs are erased from the PDM/RCDLR memory. IMPORTANT: Before proceeding with the steps below, ensure that no other sensor learn procedure is being performed simultaneously, or that tire pressures are not being adjusted on a TPM equipped vehicle within close proximity. 1. Turn "ON" the ignition, with the engine "OFF". 2. Apply the parking brake. IMPORTANT: If the learn mode cannot be enabled, ensure the TPM system is enabled in the PDM/RCDLR. 3. Cycle the exterior lamp switch from "OFF" to parking lamps 4 times within 4 seconds. A double horn chirp will sound and the low tire pressure indicator will begin to flash indicating the learn mode has been enabled. CAUTION: Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. 4. Starting with the left front tire, hold the antenna of the J-46079 against the tire sidewall close to the wheel rim at the valve stem location then press and release the activate button and wait for a horn chirp, or increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before the 8-10 second pressure increase/decrease time period has been reached, or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. 5. After the horn chirp has sounded, proceed as in step 4 for the next 3 sensors in the following order: - Right front - Right rear - Left rear 6. After the LR sensor has been learned, turn OFF the ignition to exit the learn mode. 7. After the learn mode has been exited, adjust all tire pressures to the recommended psi. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > Page 3613 Tire Pressure Module: Service and Repair Control Module Setup Passenger Door Module (PDM) Setup After passenger door module (PDM) switch assembly replacement, the following procedures must be performed in the order that they appear for the Tire Pressure Monitor (TPM) System to function properly. The PDM also requires keyless entry transmitter programming after replacement. Refer to Transmitter Synchronization. TPM System Enable The service replacement PDM switch assembly comes with the TPM System disabled to allow the same part number PDM to be used in both TPM and non-TPM equipped vehicles. Once the TPM option is enabled in the PDM, it cannot be disabled. Before proceeding with the steps below, ensure the vehicle is equipped with TPM (UJ6). Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Chassis. 4. Select Tire Pressure Monitor. 5. Select Special Functions. 6. Select TPM Option Enable. 7. Press the exit key to escape. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Chassis. 4. Select Tire Pressure Monitor. 5. Select Special Functions. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle driver door placard sticker. 9. Select the rear tire pressure as noted on the vehicle driver door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After PDM switch assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the PDM memory. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3622 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3623 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3624 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3625 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3626 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 3627 Tire Pressure Sensor: Description and Operation Tire Pressure Monitor Description and Operation The Tire Pressure Monitor (TPM) system warns the driver when a significant loss of tire pressure occurs in any of the 4 tires, and (w/UK3) allows the driver to display the individual tire pressures, and their locations on the driver information center (DIC). The system uses the powertrain control module (PCM), body control module (BCM), instrument panel cluster (IPC), DIC, passenger door module (PDM) (w/YE9/5B5), remote control door lock receiver (RCDLR) (w/o YE9/5B5), a radio frequency (RF) transmitting pressure sensor in each wheel/tire assembly, and the serial data circuit to preform the system functions. When the vehicle is stationary and the sensor internal roll switches are open for at least 30 seconds, the sensors go into stationary mode. In this mode, the sensors sample tire pressure once every 20 seconds and transmit a stationary mode transmission once every 60 minutes. As vehicle speed increases, centrifugal force closes the sensor internal roll switch causing the sensors to go into drive mode. In this mode, the sensors sample tire pressure once every 30 seconds and transmit a drive mode transmission once every 60 seconds. The PDM/RCDLR receives and translates the data contained in each sensor RF transmission into sensor presence, sensor mode, and tire pressure. The PDM (w/UK3) then sends the tire pressure and tire location data to the DIC via the serial data circuit, where they are displayed as follows: ^ LF TIRE XX PSI ^ RF TIRE XX PSI ^ RR TIRE XX PSI ^ LR TIRE XX PSI The sensors continuously compare their current pressure sample with their last pressure sample and will transmit in re-measure mode whenever a 1.6 psi change in tire pressure has occurred. When the TPM system detects a significant loss of tire pressure, the CHECK TIRE PRESSURE message is displayed on the DIC and the low tire pressure indicator is displayed on the IPC. Both the DIC message and IPC indicator can be cleared by adjusting the tire pressure to the recommended kPa/psi. Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. The sensor pressure range is 0 - 703 kPa (0 - 102 psi). The sensor pressure accuracy from -10 to +70°C (+14 to +158°F) is plus or minus 14 kPa (2 psi). The PDM/RCDLR has the ability to detect malfunctions within the TPM system. Any malfunction detected will cause the DIC to display the SERVICE TIRE MONITOR message. For more information on other functions of the PDM/RCDLR, refer to the following: ^ Keyless Entry System Description and Operation ^ Power Door Locks Description and Operation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Grommet Replacement Tire Pressure Sensor Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire/wheel assembly from the vehicle. 3. Remove the tire from the wheel. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: ^ Place the sensors cap and valve on a dry clean surface after removal, the cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. ^ Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. ^ Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. ^ Repeat items for inner bead. 4. Remove the tire pressure sensor nut. Important: If any tire sealant is noted upon tire dismounting, replace the sensor. Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. ^ Tighten the sensor nut to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 3630 5. Install the tire on the wheel. Important: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: ^ Position the mounting/dismounting head 180 degrees from the valve stem. ^ Position the bead transition area 45 degrees counterclockwise of the valve stem. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. ^ Repeat items for outer bead. 6. Install the tire/wheel assembly on the vehicle. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 3631 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Replacement Tire Pressure Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire/wheel assembly from the vehicle. 3. Remove the tire from the wheel. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. ^ Place the sensors cap and valve on a dry clean surface after removal, the cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. ^ When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. ^ Position the mounting/dismounting head so the tire iron, or pry bar can be Inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. ^ Repeat items for inner bead. 4. Remove the tire pressure sensor nut. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. ^ Tighten the sensor nut to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the tire on the wheel. Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Sensor Grommet Replacement > Page 3632 ^ Position the mounting/dismounting head 180 degrees from the valve stem. ^ Position the bead transition area 45 degrees counter clockwise of the valve stem. ^ Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. ^ Repeat items for outer bead. 5. Install the tire/wheel assembly on the vehicle. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor's unique identification code cannot be learned into the passenger door modules (PDMs) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 6. Lower the vehicle. 7. Learn the tire pressure sensors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Page 3633 Tire Pressure Sensor: Tools and Equipment Special Tools Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA06V307000 > Aug > 06 > Recall 06V307000: Incorrect Tire/Rim Label Wheels: Recalls Recall 06V307000: Incorrect Tire/Rim Label MAKE/MODELS: MODEL/BUILD YEARS: Cadillac/Escalade EXT 1500 2007 Cadillac/SRX 2006 Chevrolet/Avalanche 1500 2007 Chevrolet/Colorado 2007 Chevrolet/Silverado 2006 GMC/Canyon 2007 GMC/Sierra 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 06V307000 MFG'S REPORT DATE: August 09, 2006 COMPONENT: Wheels: Rim POTENTIAL NUMBER OF UNITS AFFECTED: 3227 SUMMARY: Certain sport utility vehicles and trucks fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims." These vehicles have an incomplete tire rim designation on the certification/tire label located on the driver's door edge. In addition, the label may also be missing the tire load rating on the label. Although this information is not required by the standard, if a tire of a lesser load rating is installed, the tire may not be able to sustain the loads encountered during use. CONSEQUENCE: If a customer replaces a wheel and only relies on the rim size designation that is indicated on the label, a wheel that is of a different rim contour designation may be installed. It may be difficult or impossible to mount the tire on a wheel with the wrong contour. If the tire is mounted on the wheel with the wrong contour, the wheel and tire may not perform as intended, which could increase the risk of a crash. REMEDY: A label that will correct the label originally installed will be mailed to consumers along with installation instructions. The customer will have the option for dealers to install the label. The manufacturer did not provide an owner notification schedule. Owners should contact Cadillac at 1-866-982-2239, Chevrolet at 1-800-630-2438, and GMC TRUCKS at 1-866-996-9463. NOTES: GM recall No. 06079. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3652 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3653 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3654 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3659 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3664 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3665 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3666 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3671 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3677 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3678 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3679 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3684 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3689 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3690 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3695 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3696 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3697 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3702 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3707 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3708 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3709 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3718 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3723 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3724 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3725 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3726 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3727 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3728 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3729 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3730 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA06V307000 > Aug > 06 > Recall 06V307000: Incorrect Tire/Rim Label Wheels: All Technical Service Bulletins Recall 06V307000: Incorrect Tire/Rim Label MAKE/MODELS: MODEL/BUILD YEARS: Cadillac/Escalade EXT 1500 2007 Cadillac/SRX 2006 Chevrolet/Avalanche 1500 2007 Chevrolet/Colorado 2007 Chevrolet/Silverado 2006 GMC/Canyon 2007 GMC/Sierra 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 06V307000 MFG'S REPORT DATE: August 09, 2006 COMPONENT: Wheels: Rim POTENTIAL NUMBER OF UNITS AFFECTED: 3227 SUMMARY: Certain sport utility vehicles and trucks fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims." These vehicles have an incomplete tire rim designation on the certification/tire label located on the driver's door edge. In addition, the label may also be missing the tire load rating on the label. Although this information is not required by the standard, if a tire of a lesser load rating is installed, the tire may not be able to sustain the loads encountered during use. CONSEQUENCE: If a customer replaces a wheel and only relies on the rim size designation that is indicated on the label, a wheel that is of a different rim contour designation may be installed. It may be difficult or impossible to mount the tire on a wheel with the wrong contour. If the tire is mounted on the wheel with the wrong contour, the wheel and tire may not perform as intended, which could increase the risk of a crash. REMEDY: A label that will correct the label originally installed will be mailed to consumers along with installation instructions. The customer will have the option for dealers to install the label. The manufacturer did not provide an owner notification schedule. Owners should contact Cadillac at 1-866-982-2239, Chevrolet at 1-800-630-2438, and GMC TRUCKS at 1-866-996-9463. NOTES: GM recall No. 06079. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3740 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3741 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3742 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3747 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3752 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3753 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3758 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3759 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3760 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3765 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3770 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3771 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3772 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3781 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3786 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3787 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3788 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3789 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3790 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3791 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3792 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3793 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3799 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3800 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3801 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3806 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3811 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3812 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3821 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3822 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3823 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3824 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3825 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3826 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3827 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3828 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > NHTSA06V307000 > Aug > 06 > Recall 06V307000: Incorrect Tire/Rim Label Wheels: All Technical Service Bulletins Recall 06V307000: Incorrect Tire/Rim Label MAKE/MODELS: MODEL/BUILD YEARS: Cadillac/Escalade EXT 1500 2007 Cadillac/SRX 2006 Chevrolet/Avalanche 1500 2007 Chevrolet/Colorado 2007 Chevrolet/Silverado 2006 GMC/Canyon 2007 GMC/Sierra 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 06V307000 MFG'S REPORT DATE: August 09, 2006 COMPONENT: Wheels: Rim POTENTIAL NUMBER OF UNITS AFFECTED: 3227 SUMMARY: Certain sport utility vehicles and trucks fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims." These vehicles have an incomplete tire rim designation on the certification/tire label located on the driver's door edge. In addition, the label may also be missing the tire load rating on the label. Although this information is not required by the standard, if a tire of a lesser load rating is installed, the tire may not be able to sustain the loads encountered during use. CONSEQUENCE: If a customer replaces a wheel and only relies on the rim size designation that is indicated on the label, a wheel that is of a different rim contour designation may be installed. It may be difficult or impossible to mount the tire on a wheel with the wrong contour. If the tire is mounted on the wheel with the wrong contour, the wheel and tire may not perform as intended, which could increase the risk of a crash. REMEDY: A label that will correct the label originally installed will be mailed to consumers along with installation instructions. The customer will have the option for dealers to install the label. The manufacturer did not provide an owner notification schedule. Owners should contact Cadillac at 1-866-982-2239, Chevrolet at 1-800-630-2438, and GMC TRUCKS at 1-866-996-9463. NOTES: GM recall No. 06079. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check Wheels: Service and Repair Wheel Mounting Surface Check Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203-229 mm (8-9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. 4. Replace the wheel if the wheel is bent. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check > Page 3835 Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: ^ The load capacity ^ The wheel diameter ^ The rim width ^ The wheel offset ^ The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: ^ Wheel and hub-bearing life ^ Brake cooling ^ Speedometer/odometer calibration ^ Vehicle ground clearance ^ Tire clearance to the body and the chassis 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check > Page 3836 Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check > Page 3837 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Caution: To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Important ^ Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. ^ Inspect the wheel for cracks. If cracks are found, discard the wheel. ^ ALL wheels with bent rim flanges must not be repaired or refinished. ^ The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. ^ Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options ^ Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). ^ If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option #2). ^ Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources ^ The Paint Manufactures Color Book ^ Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. ^ To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. ^ A Color Compatibility chart is also at this site defining what colors are used on what models. ^ Important: Chemical strippers are not recommended. Refer to specific Paint Manufactures for refinish procedures and process pertaining to "Aluminum Refinishing".The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection ^ If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. ^ Some specific colors may be recommended on certain models (currently SSR and GTO). ^ If painting wheels that were previously clearcoated aluminum, it is recommended that all four wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures-Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. 5. Clean and mask and paint the wheels. Important: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. General Refinishing Procedures-Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. 3. Install NEW coated balance weights at marked locations. Important: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 4. Install wheels on vehicle. Important: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check > Page 3838 the vehicle. The star pattern must be followed. Repair Option Number 2. Outside Companies ^ Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800–892–3733), provides this service with GM guidelines. Other companies may also exist. ^ Any process that re-machines or otherwise remanufactures the wheel should not be used. ^ The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. ^ Paint and/or clearcoat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. ^ A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check > Page 3839 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel Mounting Surface Check > Page 3840 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (RWD) Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the rotor. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel hub and bearing (4) 15-series mounting bolts. 6. Remove the wheel hub and bearing mounting bolts (4), the 25/35 series. 7. Remove the wheel hub and bearing and splash shield from the vehicle. 8. Remove the O-ring seal from the steering knuckle bore, the 25/35 series. 9. Remove the wheel speed sensor mounting bolt (5). 10. Clean and inspect the O-ring seal, the 25/35 series. 11. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Page 3844 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, 25/35 series. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Install the wheel speed sensor mounting bolt. Tighten Tighten the bolt to 18 N.m (13 lb ft). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Page 3845 6. Install the wheel hub and bearing (4) and splash shield to the 15-series steering knuckle. 7. Install the wheel hub and the 15-series bearing mounting bolts. Install the wheel hub and bearing mounting bolts, the 25/35 series. Tighten Tighten the bolts to 180 N.m (133 lb ft). 8. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. Tighten Tighten the brake hose clip bolt to 12 N.m (106 lb in). 9. Install the rotor. 10. Install the tire and wheel. 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure > Page 3850 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Hub Nut (10.5/11.5 Inch Axles) ....................................................................................................................................................... 70 Nm (52 lb ft) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3859 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3860 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3861 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3862 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nut Torque ............................................................................................................................... ..................................................... 140 ft lb (190 Nm) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 3866 Wheel Nut Torque Sequence Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3869 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3870 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 3874 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 1. Place the automatic transmission in PARK. 2. Block the wheels. 3. Set the parking brake. 4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. Consult the vehicle's owner's manual for proper connections. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery.If the engine does not crank or cranks too slowly, perform the following steps: 0. Turn the ignition OFF. 1. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 2. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > General Information Vehicle Lifting: Service and Repair General Information LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > General Information > Page 3880 Vehicle Lifting: Service and Repair Frame Contact Lift FRAME CONTACT HOIST FRONT HOIST PADS IMPORTANT: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. REAR HOIST PADS IMPORTANT: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > General Information > Page 3881 Vehicle Lifting: Service and Repair Suspension Contact Lift SUSPENSION CONTACT HOIST FRONT LIFT Position the front lift under the outer edge of the front suspension lower control arms. REAR LIFT Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > General Information > Page 3882 Vehicle Lifting: Service and Repair Vehicle Jacking JACKING When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails IMPORTANT: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder should read less than ............................................................................................................................................................ 690 kPa (100 psi). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3888 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 5 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Raise the hood to the service position, perform the following: ^ Remove the hood hinge bolts (1). ^ Raise the hood until vertical. ^ Install the hood hinge bolts until snug in the service position (2). 2. Remove the radiator support. 3. Remove the oil pump, screen, and crankshaft oil deflector. 4. Remove the valve lifters. 5. Remove the camshaft sensor bolt and sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3893 6. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. 7. Remove the camshaft sprocket bolts. Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 8. Remove the camshaft sprocket and reposition the timing chain. 9. Remove the camshaft retainer bolts and retainer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3894 Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 10. Remove the camshaft. 10.1 Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. 10.2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. 10.3. Remove the three bolts from the camshaft. 11. If required, clean and inspect the camshaft and bearings. Installation Procedure Important: If camshaft replacement is required, the valve lifters must also be replaced. 1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Using the bolts as a handle, carefully install the camshaft into the engine block. 4. Remove the three bolts from the front of the camshaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3895 Notice: Refer to Fastener Notice in Service Precautions. Important: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. 5. Install the camshaft retainer and bolts. Tighten Tighten the bolts to 25 Nm (18 lb ft). 6. Install the camshaft sprocket and position the timing chain. 7. Install the camshaft sprocket bolts. Tighten Tighten the bolts to 35 Nm (26 lb ft). 8. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused. 9. Lubricate the O-ring seal with clean engine oil. 10. Install the camshaft sensor and bolt. Tighten Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3896 Tighten the bolt to 25 Nm (18 lb ft). 11. Install the valve lifters. 12. Install the oil pump, screen, and crankshaft oil deflector. 13. Install the radiator support. 14. Remove the hood hinge bolts from the service position (2). 15. Lower the hood to the normal position. 16. Install the hood hinge bolts. Tighten Tighten the bolts to 25 Nm (18 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement ^ Tools Required J 3049-A Valve Lifter Remover Removal Procedure 1. Remove the cylinder head and gasket. 2. Remove the valve lifter guide bolts. 3. Remove the valve lifters and guide. Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits. 4. Use J 3049-A or equivalent in order to remove the valve lifters, if required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 3900 5. Remove the valve lifters from the guide. 6. Organize or mark the components so that they can be installed in the same location from which they were removed. 7. If required, clean and inspect the valve lifters. Installation Procedure Important: When reusing valve lifters, install the lifters to their original locations. 1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. 3. Install the valve lifters and guide to the engine block. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 3901 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve lifter guide bolts. Tighten Tighten the bolt to 12 Nm (106 lb in). 5. Install the cylinder head and gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Important: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. 4. Remove the rocker arm pivot support. 5. Remove the pushrods. 6. If required, clean and inspect the rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3905 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Important: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3906 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following rocker arm bolts: Tighten ^ Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). ^ Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: Tighten ^ Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). ^ Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the rocker arm cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Important: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. 4. Remove the rocker arm pivot support. 5. Remove the pushrods. 6. If required, clean and inspect the rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3910 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3911 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following rocker arm bolts: ^ Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: ^ Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the rocker arm cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance - Production ....................................................................................................... 0.023-0.065 mm (0.0009-0.0025 inch) Connecting Rod Bearing Clearance - Service .............................................................................................................. 0.023-0.076 mm (0.0009-0.003 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque Connecting Rod: Technical Service Bulletins Engine - Revised Connecting Rod Bolt Torque Bulletin No.: 07-06-01-002 Date: March 05, 2007 INFORMATION Subject: Information on Revised Connecting Rod Bolt Torque for Small Block GEN III and GEN IV Vortec(TM) V8 Engines Models A new connecting rod bolt torque specification was introduced to the GEN III and GEN IV Vortec(TM) small block V8 engines. The connecting rod bolts should continue to be tightened using two passes. The second pass value has been increased from 75 degrees to 85 degrees. Install the connecting rod bolts and tighten. Refer to Piston, Connecting Rod, and Bearing Installation in SI. Tighten Tighten the connecting rod bolts a first pass to 20 N.m (15 lb ft). Tighten the connecting rod bolts a final pass to 85 degrees using the J 45059 Angle Meter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque > Page 3920 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 3921 Connecting Rod: Specifications The contents of this article have been updated by TSB # 07-06-01-002 dated 3/5/2007. Connecting Rod Bolts - First Pass ............................................................................................................................................................. 20 Nm (15 ft. lbs.) Connecting Rod Bolts - Final Pass ........................................................................ ................................................................................................. 85 degrees Connecting Rod Bore Diameter - Bearing End ......................................................................................................... 56.505-56.525 mm ( 2.224-2.225 inch) Connecting Rod Bore Out-of-Round - Bearing End Production ............................................................................ 0.004-0.008 mm (0.00015-0.0003 inch) Connecting Rod Bore Out-of-Round - Bearing End - Service ................................................................................. 0.004-0.008 mm (0.00015-0.0003 inch) Connecting Rod Side Clearance ....................................................................................................................................... 0.11-0.51 mm (0.00433-0.02 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Main Bearing Bolts Crankshaft Bearing Cap M8 Bolts ......................................................................................................................................................... 25 Nm (18 ft. lbs.) Crankshaft Bearing Cap M10 Bolts - First Pass in Sequence ................................................................................................................ 20 Nm (15 ft. lbs.) Crankshaft Bearing Cap M10 Bolts - Final Pass in Sequence ............................................................................................................................ 80 degrees Crankshaft Bearing Cap M10 Studs - First Pass in Sequence ................................................................................................................ 20 Nm (15 ft. lbs.) Crankshaft Bearing Cap M10 Studs - Final Pass in Sequence ........................................................................................................................... 51 degrees Crankshaft Main Bearing Clearance - Production ........................................................................................................ 0.02-0.052 mm (0.0008-0.0021 inch) Crankshaft Main Bearing Clearance - Service ............................................................................................................. 0.02-0.065 mm (0.0008-0.0025 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Connecting Rod Journal Diameter - Production ..................................................................................................... 53.318-53.338 mm (2.0991-2.0999 inch) Connecting Rod Journal Diameter - Service .................................................................................................................................. 53.308 mm (2.0987 inch) Connecting Rod Journal Out-of-Round - Production ....................................................................................................................... 0.005 mm ( 0.0002 inch) Connecting Rod Journal Out-of-Round - Service ............................................................................................................................... 0.01 mm (0.0004 inch) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production ........................................................................ 0.005 mm (0.0002 inch) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service .............................................................................. 0.02 mm (0.00078 inch) Crankshaft End Play ......................................................................................................................................................... 0.04-0.2 mm (0.0015-0.0078 inch) Crankshaft Main Journal Diameter - Production ........................................................................................................ 64.992-65.008 mm (2.558-2.559 inch) Crankshaft Main Journal Diameter - Service .................................................................................................................................... 64.992 mm (2.558 inch) Crankshaft Main Journal Out-of-Round - Production ................................................................................................................... 0.003 mm (0.000118 inch) Crankshaft Main Journal Out-of-Round - Service ............................................................................................................................ 0.008 mm (0.0003 inch) Crankshaft Main Journal Taper - Production ...................................................................................................................................... 0.01 mm (0.0004 inch) Crankshaft Main Journal Taper - Service ......................................................................................................................................... 0.02 mm (0.00078 inch) Crankshaft Rear Flange Runout ............................................................................................................................................................ 0.05 mm (0.002 inch) Crankshaft Reluctor Ring Runout - Measured 1.0 mm ((0.04 inch) Below Tooth Diameter .................................................................. 0.7 mm (0.028 inch) Crankshaft Thrust Surface - Production ....................................................................................................................... 26.14-26.22 mm (1.029-1.0315 inch) Crankshaft Thrust Surface - Service ................................................................................................................................................. 26.22 mm (1.0315 inch) Crankshaft Thrust Surface Runout ...................................................................................................................................................... 0.025 mm (0.001 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3936 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3937 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3938 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3939 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3945 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3946 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3947 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3948 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Raise and suitably support the vehicle. 3. Disconnect the coolant heater electrical connector (2). 4. Important: Do not score the surface of the engine block hole when removing the coolant heater. Remove the coolant heater from the engine block. 5. Remove any burrs, sealer, paint or other rough spots. Installation Procedure 1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the coolant heater to the engine block. ^ Tighten the coolant heater to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 3951 3. Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. 5. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 3952 Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the coolant heater electrical connector (2). 3. Remove the coolant heater cord retainer and bolts. 4. Remove the coolant heater cord. Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 1. Install the coolant heater cord. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant heater cord bolts and retainer. ^ Tighten the bolts to 8 Nm (71 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 3953 3. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Service and Repair Engine Valley Cover: Service and Repair Engine Valley Cover Replacement Removal Procedure 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. 5. Remove the engine valley cover bolts. 6. Remove the engine valley cover and gasket. 7. Discard the old gasket. 8. Remove the knock sensor oil seals (1) from the cover (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Service and Repair > Page 3957 9. If required, clean and inspect the engine valley cover. Installation Procedure Important: All gasket surfaces should be free of oil or other foreign material during assembly. 1. Lubricate the NEW knock sensor seals (1) with clean engine oil. 2. Install the knock sensor oil seals (1) into the engine valley cover (2). 3. Install the engine valley cover with a NEW gasket onto the engine block. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine valley cover bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 5. Install the knock sensors. ^ Tighten the sensors to 20 Nm (15 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Service and Repair > Page 3958 6. Connect the knock sensor electrical connectors. 7. Push down on the rubber covers. 8. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes ............... 50 Nm (37 ft. lbs.) Crankshaft Balancer Bolt - Final Pass ................................................................................................. ................................................................. 140 degrees Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3962 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement (4.8L, 5.3L, and 6.0L Engines) ^ Tools Required J 41816 Crankshaft Balancer Remover - J 41816-2 Crankshaft End Protector - J 42386-A Flywheel Holding Tool - J 41665 Crankshaft Balancer and Sprocket Installer - J 45059 Angle Meter Removal Procedure 1. Remove the air conditioning (A/C) drive belt. 2. Remove the fan shroud - lower. 3. Remove the starter motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Important: ^ Make sure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. ^ The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. Install the J 42386-A and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. ^ Tighten the J 42386-A bolts to 50 Nm (37 ft. lbs.). 5. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3963 6. Use the J 41816 and J 41816-2 in order to remove the crankshaft balancer. 7. Remove the J 41816 and the J 41816-2 from the crankshaft balancer. 8. Clean and inspect the crankshaft balancer. Installation Procedure Important: ^ Make sure that the teeth of J 42386-A mesh with the teeth of the engine flywheel. ^ The used crankshaft balancer bolt will be used only during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and forth passes of the balancer bolt tightening procedure. ^ The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and forth passes tighten the new bolt to the proper torque. Important: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Install the crankshaft balancer onto the end of the crankshaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3964 2. Use the J 41665 in order to install the crankshaft balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the balancer installation tool. 3. Install the used crankshaft balancer bolt. ^ Tighten the USED crankshaft balancer bolt to 330 Nm (240 ft. lbs.). 4. Remove the used crankshaft balancer bolt. Important: The nose of the crankshaft should be recessed 2.4 - 4.48 mm (0.094 - 0.176 inch) into the balancer bore. 5. Measure for a correctly installed balancer .If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. 6. Install a NEW crankshaft balancer bolt. 1. Tighten the bolt a first pass to 50 Nm (37 ft. lbs.). 2. Tighten the bolt a second pass to 140 degrees using J 45059 . 7. Remove the J 42386-A and bolts. 8. Install the starter motor. 9. Install the fan shroud - lower. 10. Install the A/C drive belt. 11. Perform the crankshaft position (CKP) system variation learn procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston - Piston Diameter - Measured Over Skirt Coating ............................................................................................. 96.002-96.036 mm (3.779-3.78 inch) Piston - Piston to Bore Clearance - Production ........................................................................................... -0.036 to +0.016 mm (-0.0014 to +0.0006 inch) Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off .............................................................................. 0.071 mm (0.0028 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Pin - Piston Pin Clearance to Piston Pin Bore - Production ....................................................................................... 0.002-0.01 mm (0.00008-0.0004 inch) Pin Piston Pin Clearance to Piston Pin Bore - Service ........................................................................................... 0.002-0.015 mm (0.00008-0.0006 inch) Pin - Piston Pin Diameter ........................................................................................................................................... 23.952-23.955 mm (0.943-0.943 inch) Pin - Piston Pin Fit inch) Connecting Rod Bore - Production .................................................................................. 0.007-0.02 mm (0.00027-0.00078 inch) Pin Piston Pin Fit inch) Connecting Rod Bore - Service ..................................................................................... 0.007-0.022 mm (0.00027-0.00086 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring End Gap - First Compression Ring - Measured inch) Cylinder Bore - Production ......................................... 0.23-0.44 mm (0.009-0.017 inch) Piston Ring End Gap - First Compression Ring - Measured inch) Cylinder Bore - Service .............................................. 0.23-0.5 mm (0.009-0.0196 inch) Piston Ring End Gap - Second Compression Ring - Measured inch) Cylinder Bore - Production ...................................... 0.44-0.7 mm (0.017-0.027 inch) Piston Ring End Gap - Second Compression Ring - Measured inch) Cylinder Bore - Service .......................................... 0.44-0.76 mm (0.0173-0.03 inch) Piston Ring End Gap - Oil Control Ring - Measured inch) Cylinder Bore - Production .................................................... 0.18-0.75 mm (0.007-0.029 inch) Piston Ring End Gap - Oil Control Ring - Measured inch) Cylinder Bore Service ......................................................... 0.18-0.81 mm (0.007-0.032 inch) Piston Ring to Groove Clearance - First Compression Ring - Production ............................................................... 0.04-0.085 mm (0.00157-0.00335 inch) Piston Ring to Groove Clearance - First Compression Ring - Service ..................................................................... 0.04-0.085 mm (0.00157-0.00335 inch) Piston Ring to Groove Clearance - Second Compression Ring - Production ............................................................. 0.04-0.078 mm (0.00157-0.0031 inch) Piston Ring to Groove Clearance - Second Compression Ring - Service ................................................................... 0.04-0.078 mm (0.00157-0.0031 inch) Piston Ring to Groove Clearance - Oil Control Ring - Production ................................................................................ 0.012-0.2 mm (0.0005-0.0078 inch) Piston Ring to Groove Clearance - Oil Control Ring - Service ...................................................................................... 0.012-0.2 mm (0.0005-0.0078 inch) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair Rear Engine Plate: Service and Repair Engine Rear Cover Replacement ^ Tools Required J 41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the engine flywheel. 2. Remove the oil pan-to-rear cover bolts (1). 3. Remove the rear cover bolts. 4. Remove the rear cover and gasket. 5. Discard the rear cover gasket. 6. If required, clean and inspect the rear cover. Installation Procedure Important: ^ Do not reuse the crankshaft oil seal or rear cover gasket. ^ Do not apply any type of sealant to the rear cover gasket, unless specified. ^ The special tool in this procedure is used to properly center the crankshaft rear oil seal. ^ The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned. Install the rear cover without the crankshaft oil seal. ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ The crankshaft rear oil seal MUST be centered in relation to the crankshaft. ^ An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3977 1. Apply a 5 mm (0.2 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 inch) long to the oil pan to engine block junction. 2. Install the rear cover gasket and cover. 3. Install the rear cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten. 5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface. Important: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 6. Install the J 41476 and bolts onto the rear of the crankshaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3978 Notice: Refer to Fastener Notice in Service Precaution. 7. Tighten the J 41476 mounting bolts until snug. Do not overtighten. 1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 2. Tighten the engine rear cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J 41476 . 9. Install a NEW crankshaft rear oil seal. 10. Install the engine flywheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 3984 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Important: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. 4. Remove the rocker arm pivot support. 5. Remove the pushrods. 6. If required, clean and inspect the rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3988 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3989 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following rocker arm bolts: ^ Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: ^ Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the rocker arm cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical connector (2) to the ignition coil wire harness. 4. Remove the harness clips (1). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. ^ Twist each plug wire 1/2 turn. ^ Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs. 8. Remove the ignition coil bracket. 9. Remove the positive crankcase ventilation (PCV) hose. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 3994 10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. 12. Remove and discard the old gasket (1). 13. If required, clean and inspect the rocker arm cover. Installation Procedure Important: ^ All gasket surfaces should be free of oil an/or other foreign material during assembly. ^ DO NOT reuse the valve rocker arm cover gasket. ^ If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 3995 2. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the rocker arm cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 4. Install the PCV hose. 5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket bolts. 6. Install the ignition coil bracket. 7. Install the ignition coil bracket studs. ^ Tighten the studs to 12 Nm (106 inch lbs.). 8. Install the spark plug wires to the ignition coils. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 3996 9. Position the engine harness, if necessary. 10. Install the harness clips (1). 11. Connect the main electrical connector (2) to the ignition coil wire harness. 12. Install the CPA lock. 13. Install the engine sight shield, if required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 3997 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the connector position assurance (CPA) lock (5). 3. Disconnect the main electrical connector (4) to the ignition coil wire harness. 4. Remove the harness clips (1). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. ^ Twist each plug wire 1/2 turn. ^ Pull only on the boot in order to remove the wire from the ignition coil. 7. Reposition the surge tank/heater hoses from the heater hose bracket. 8. Remove the heater hose bracket nut and bracket. 9. Remove the ignition coil bracket studs. 10. Remove the ignition coil bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 3998 11. Remove the positive crankcase ventilation (PCV) hose. 12. Loosen the valve rocker arm cover bolts. 13. Remove the valve rocker arm cover. 14. Remove and discard the old gasket (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 3999 15. Remove the oil fill tube from the rocker cover, if required. 16. If required, clean and inspect the rocker arm cover. Installation Procedure Important: ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ DO NOT reuse the valve rocker arm cover gasket. ^ If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position. 4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover lip. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 4000 5. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the rocker arm cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 7. Install the PCV hose. 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket bolts. 9. Install the ignition coil bracket. 10. Install the ignition coil bracket studs. ^ Tighten the studs to 12 Nm (106 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left > Page 4001 11. Install the heater hose bracket and nut. ^ Tighten the nut to 9 Nm (80 inch lbs.). 12. Position the surge tank/heater hoses to the heater hose bracket. 13. Install the spark plug wires to the ignition coils. 14. Position the engine harness, if necessary. 15. Install the harness clips (1). 16. Connect the main electrical connector (4) feeding the ignition coils. 17. Install the CPA lock (5). 18. Install the engine sight shield, if required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. 2. Disconnect the spark plug wire at the spark plug. ^ Twist each plug wire boot 1/2 turn. ^ Pull only on the boot in order to remove the wire from the spark plug. 3. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. Loosen the spark plug 1 or 2 turns. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 4005 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (2). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (3). 14. Remove the valve spring (4). 15. Remove the valve stem oil seal and shim (1, 5). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 4006 1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (1, 5). 4. Install the valve spring (4). 5. Install the valve spring cap (3). 6. Compress the valve spring using the J 38606 . 7. Install the valve keys. ^ Use grease in order to hold the valve keys in place. ^ Make sure the keys seat properly in the groove of the valve stem. ^ Carefully release the valve spring pressure, making sure the valve keys stay in place. ^ Remove the J 38606 . ^ Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. 8. Remove the J 22794 from the spark plug port. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 4007 9. Notice: Refer to Fastener Notice in Service Precautions. Hand start the spark plug. ^ Tighten the spark plug to 15 Nm (11 ft. lbs.). 10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug. 12. Inspect the wires for proper installation: ^ Push sideways on each boot in order to check for proper installation. ^ Reinstall any loose boot. 13. Install the rocker arm. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Engine - BULLETIN CANCELLATION NOTIFICATION Valve: Technical Service Bulletins Engine - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 07-06-01-007G Date: April 23, 2010 Subject: Excessive Engine Oil Consumption (Verify Condition, Inspect Valve Stems, Replace Cylinder Heads if Necessary) Models: 2006 Chevrolet Avalanche, Suburban, Tahoe 2006-2007 Chevrolet Silverado Classic 2006 GMC Yukon, Yukon XL 2006-2007 GMC Sierra Classic Equipped with 4.8L or 5.3L V8 Engine RPOs LR4, LM7, L59 Please Refer to GMVIS Supercede: This bulletin is being canceled because the information no longer applies. Please discard Corporate Bulletin Number 07-06-01-007F (Section 06 - Engine/Propulsion System). This bulletin is being canceled because the information no longer applies. If you encounter a vehicle with the above symptoms, please refer to SI. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 4017 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 4018 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 4019 Drive Belt: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 4020 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components ^ The power steering pump, if belt driven ^ The generator ^ The A/C compressor, if equipped ^ The engine cooling fan, if belt driven ^ The water pump, if belt driven ^ The vacuum pump, if equipped ^ The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4023 Step 1 - Step 14 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4024 Step 15 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4025 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Step 1 - Step 6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4026 Drive Belt: Testing and Inspection Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4027 Step 1 - Step 12 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4028 Drive Belt: Testing and Inspection Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Step 1 - Step 8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4029 Drive Belt: Testing and Inspection Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4030 Step 1 - Step 14 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4031 Step 15 Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Step 1 - Step 6 Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4032 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Step 1 - Step 12 Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4033 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Step 1 - Step 8 Drive Belt Squeal Diagnosis Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4034 proceed further in this table 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Step 1 - Step 9 Drive Belt Vibration Diagnosis Drive Belt Vibration Diagnosis Diagnostic Aids Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4035 The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4036 Step 1 - Step 11 Drive Belt Whine Diagnosis Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTC's) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Diagnosis > Page 4037 removal and installation procedure. Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement Drive Belt: Service and Repair Drive Belt Replacement Drive Belt Replacement - Accessory Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The mass airflow/intake air temperature (MAF/IAT) sensor 2. Disconnect the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 6. Remove the belt from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 4040 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 4041 9. Install the air cleaner outlet duct. 10. Connect the radiator inlet hose clip to the outlet duct. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 11. Tighten the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The MAF/IAT sensor Tighten Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 4042 Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement Air Conditioning Compressor Belt Replacement Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 4043 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening. 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Install the engine shield bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 4044 12. Install the accessory drive belt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure 1. Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. Remove the drive belt. 2. Move the drive belt tensioner through its full travel. ^ The movement should feel smooth. ^ There should be no binding. ^ The tensioner should return freely. 3. If any binding is observed, replace the drive belt tensioner. 4. Install the drive belt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement - Accessory Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Accessory Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. 2. Install the drive belt tensioner bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt tensioner bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the accessory drive belt Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement - Accessory > Page 4050 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Air Conditioning Drive Belt Tensioner Replacement - Air Conditioning Removal Procedure 1. Remove the air conditioning (A/C) drive belt. 2. Remove the A/C belt tensioner bolts. 3. Remove the A/C belt tensioner. Installation Procedure 1. Install the A/C belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the A/C belt tensioner bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the A/C drive belt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. 1. Apply the park brake. 2. Start the engine. 3. Firmly apply and hold the primary brakes. 4. Have an assistant stand to the side of the vehicle in order to observe for engine movement. 5. Slightly load the engine shifting from drive to reverse a few times. 6. If the engine moves more than 24 mm (0.945 inch) from the at rest position, in either direction, check for loose engine mount bolts. 2. If the engine mount bolt torque is within specifications, check the condition of the engine mount. 3. Replace the engine mount if any of the following conditions exist: ^ Heat check cracks cover the rubber cushion surface. ^ The rubber cushion is separated from the metal plate of the mount. ^ There is a split through the rubber cushion. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left Engine Mount: Service and Repair Engine Mount Bracket Replacement - Left Engine Mount Bracket Replacement - Left Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine mount bracket bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply threadlocker GM P/N 12345382 ( Canadian P/N 10953489) or equivalent to the bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine mount bracket bolts. ^ Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 4. Install the engine mount. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4056 Engine Mount: Service and Repair Engine Mount Bracket Replacement - Right Engine Mount Bracket Replacement - Right Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine mount bracket bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply threadlocker GM P/N 12345382 ( Canadian P/N 10953489) or equivalent to the bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine mount bracket bolts. ^ Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 4. Install the engine mount. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4057 Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Removal Procedure Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Raise the vehicle. 2. Remove the tire and wheel. 3. Remove the wheelhouse panel from the vehicle. 4. For vehicles with 4WD, remove the front propeller shaft. 5. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. Raise and suitably support the engine using adjustable (screw type) jack stands. 6. Remove the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). 7. Remove the engine mount bolts. 8. Remove the left engine mount. Installation Procedure 1. Install the left engine mount to the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4058 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts to the engine. ^ Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. For vehicles with 4WD, install the front propeller shaft. 6. Install the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). ^ Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.). 7. Install the wheelhouse panel from the vehicle. 8. Install the tire and wheel. 9. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4059 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Removal Procedure 1. Remove the exhaust manifold. 2. Remove the engine mount-to-engine mount bracket bolts. 3. Raise and suitably support the vehicle. 4. Remove the tire and wheel. 5. Remove the inner wheelhouse panel. 6. Remove the engine protection shield, if equipped. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. 7. Raise and suitably support the engine using adjustable (screw type) jack stands. 8. Remove the engine mount to engine bolts. 9. Remove the right engine mount. Installation Procedure 1. Position the right engine mount to the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4060 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts. ^ Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. Install the engine mount-to-engine mount bracket bolts. ^ Tighten the engine mount-to-engine mount bracket bolts to 65 Nm(48 ft. lbs.). 6. Install the exhaust manifold. 7. Install the inner wheelhouse panel. 8. Install the tire and wheel. 9. Install the engine protection shield, if equipped. 10. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the drive belt idler pulley bolt. 2. Remove the accessory drive belt. 3. Remove the drive belt idler pulley and bolt. Installation Procedure 1. Install the drive belt idler pulley and bolt to the generator bracket. Snug the bolt finger tight. 2. Install the drive belt. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt idler pulley bolt. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot 41 kPa at 1,000 engine RPM (6 psig at 1,000 engine RPM) 124 kPa at 2,000 engine RPM (18 psig at 2,000 engine RPM) 165 kPa at 4,000 engine RPM (24 psig at 4,000 engine RPM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 4068 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing ^ Tools Required J 21867 Pressure Gage - J 42907 Oil Pressure Tester 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: ^ Oil diluted by water or glycol antifreeze ^ Foamy oil 6. Remove the oil filter and install the J 42907 . 7. Install the J 21867, or equivalent to the J 42907 . 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L33 VIN B) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N) . 10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: ^ Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection . ^ Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation . ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure relief valve ^ Excessive bearing clearance ^ Cracked, porous, or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation . ^ Broken valve lifters Repair as necessary. 11. If the oil pressure reading on the J 21867, or equivalent, is within specifications, inspect for the following conditions: ^ Plugged or incorrect oil filter and/or malfunctioning oil bypass valve ^ Malfunctioning oil pressure gage or sensor. Repair, as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine block. 4. Important: The O-ring seal may be reused if not cut or damaged. Inspect the O-ring seal for cuts or damage. 5. Remove the O-ring seal from the tube, if required. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 4072 1. Lubricate the O-ring seal with clean engine oil. 2. Install a NEW O-ring seal onto the oil level indicator tube, if required. 3. Install the oil level indicator tube between the exhaust manifold and engine block. 4. Raise and suitably support the vehicle. 5. Install the oil level indicator tube into the block. The tube must be installed with the collar flush to the block. 6. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil level indicator tube bolt ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 8. Install the oil level indicator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 4077 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 4078 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 4081 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE Look for two things: 1.GM6094M Your vehicle's engine requires oil meeting GM Standard GM6094M. 2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container, and use only those oils that are identified as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 4082 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 4083 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure 1. Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. ^ Install a new retaining ring into each quick connector fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4088 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4089 6. Important: Do not manually depress the retaining clip when installing the plastic cap. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4090 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement (2WD) Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disconnect the engine oil cooler quick connect fittings. 2. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Raise and suitably support the vehicle. 4. If equipped with a 8.1L engine, perform the following: 5. Remove the oil cooler hoses from the clip. 6. Raise and suitably support the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4091 7. If equipped, remove the engine shield bolts. 8. Remove the engine shield. 9. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Remove the oil cooler hose bracket bolt (1). 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4092 10. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hose bracket bolt. 2. Disconnect the quick connect fittings (1) at the engine. 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Installation Procedure 1. Important: A distinct snap should be heard when assembling the tube ends of the hose assembly to the quick connectors. To ensure the tube is fully inserted into the connector, check by giving the tube a forceful pull. If equipped with a 8.1L engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Connect the quick connect fittings (1) at the engine. 3. Notice: Refer to Fastener Notice in Cautions and Notices. Install the oil cooler hose bracket bolt. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). 2. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil cooler hose bracket bolt (1). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4093 3. If equipped, install the engine shield. 4. Install the engine shield bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. 6. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4094 7. Important: o Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. ^ Do not use the plastic cap in order to install the cooler line into the fitting. ^ If equipped with a 8.1L engine perform the following: 8. Install the oil cooler hoses to the clip. 9. Connect the engine oil cooler quick connect fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 4099 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 4100 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil filter adapter (1). ^ Tighten the adapter to 55 Nm (40 ft. lbs.). 2. Install the oil filter. 3. Refill the engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level sensor to the oil pan. ^ Tighten the sensor to 13 Nm (115 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair > Page 4107 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan M6 Bolts - Oil Pan-to-Rear Housing ....................................................................................................................................... 12 Nm (106 inch lbs.) Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover ................................................................................................ 25 Nm (18 ft. lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement Oil Pan: Service and Repair Oil Pan Cover Replacement Oil Pan Cover Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil pan cover bolts (1), cover (2), and gasket (3). 3. Discard the gasket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install a new oil pan cover gasket (3), the cover (2) and bolts (1). ^ Tighten the bolts to 12 Nm (106 inch lbs.). 2. Refill the engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4116 Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement Removal Procedure 1. If equipped with four wheel drive (4WD), remove the inner axle housing nuts and washers from the bracket. 2. Support the front drive axle with a suitable jack. 3. If equipped with 4WD, remove the differential carrier lower mounting bolt and nut. 4. If equipped with 4WD, remove the differential carrier upper mounting bolt and nut. 5. Lower the front drive axle. 6. Remove the transmission cover bolt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4117 7. If equipped, remove the oil pan skid plate bolts. 8. Remove the oil pan skid plate. 9. Remove the crossbar bolts. 10. Remove the crossbar. 11. Remove the transmission cover bolt and cover. 12. Drain the engine oil and remove the engine oil filter. 13. Re-install the drain plug and oil filter until snug. 14. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4118 15. Remove the bottom bolt on the left side. 16. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts. 17. Disconnect the oil level sensor electrical connector (3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4119 18. Remove the battery cable channel bolt. 19. Slide the channel pin out of the oil pan tab. 20. Remove the following from the positive battery cable clip: ^ Engine wiring harness clip ^ Positive battery cable clip 21. Remove the engine oil cooler lines from the positive battery cable clip. 22. Remove the positive battery cable clip bolt and clip. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4120 23. Remove the oil pan bolts. 24. Remove the oil pan. 25. Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. Drill (3) out the oil pan gasket retaining rivets (2), if required. 26. Remove the gasket (1) from the pan. 27. Discard the gasket and rivets. 28. If required, clean and inspect the engine oil pan. Installation Procedure Important: ^ The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. ^ Do not reuse the oil pan gasket. ^ It is not necessary to rivet the NEW gasket to the oil pan. 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4121 2. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 inch) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. 3. Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. Pre-assemble the oil pan gasket to the pan. ^ Install the gasket onto the pan. ^ Install the oil pan bolts to the pan and through the gasket. 4. Install the oil pan, gasket and bolts to the engine block. 5. Tighten the oil pan bolts until snug. Do not overtighten. 6. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4122 7. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the bottom bolt on the left side until snug. 1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 Nm (18 ft. lbs.). 2. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 3. Tighten the bellhousing, converter cover, and transmission bolts/stud to 50 Nm (37 ft. lbs.). 9. Install the positive battery cable clip and bolt to the oil pan. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 10. Install the engine oil cooler lines to the positive battery cable clip. 11. Install the following to the positive battery cable clip: ^ Engine wiring harness clip ^ Positive battery cable clip Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4123 12. Slide the channel pin in to the oil pan tab. 13. Install the battery cable channel bolt. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 14. Connect the oil level sensor electrical connector (3). 15. Install the transmission cover and bolt. ^ Tighten the bolt to 12 Nm (106 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4124 16. Install the crossbar. 17. Install the crossbar bolts. ^ Tighten the bolts to 100 Nm (74 ft. lbs.). 18. If equipped, install the oil pan skid plate. 19. Install the oil pan skid plate bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 20. Install the transmission cover bolts ^ Tighten the bolt to 12 Nm (106 inch lbs.). 21. Raise the front drive axle into position. 22. If equipped with 4WD, install the differential carrier upper mounting bolt and nut until snug. Do not tighten at this time. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 4125 23. If equipped with 4WD, install the differential carrier lower mounting bolt and nut. ^ Tighten the bolts to 100 Nm (75 ft. lbs.). 24. If equipped with 4WD, install the inner axle housing washers and nuts to the bracket. ^ Tighten the nuts to 100 Nm (75 ft. lbs.). 25. Remove the jack from the front drive axle. 26. Install new engine oil and a new oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Page 4132 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump, Screen and Crankshaft Oil Deflector Replacement Removal Procedure 1. Remove the oil pan. 2. Remove the engine front cover. 3. Remove the oil pump screen bolt and nuts. 4. Remove the oil pump screen with O-ring seal. 5. Remove the O-ring seal from the pump screen. 6. Discard the O-ring seal. 7. Remove the remaining crankshaft oil deflector nuts. 8. Remove the crankshaft oil deflector. 9. Remove the oil pump bolts. Important: Do not allow dirt or debris to enter the oil pump assembly, cap end as necessary. 10. Remove the oil pump. 11. If required, clean and inspect the oil pump. Refer to Oil Pump Cleaning and Inspection . Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 4136 1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. 2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pump bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 4. Install the crankshaft oil deflector and nuts until snug. 5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil. 6. Install the NEW O-ring seal onto the oil pump screen. Important: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs. 7. Install the oil pump screen. 8. Install the oil pump screen bolt and nuts. 1. Tighten the bolt to 12 Nm (106 inch lbs.). 2. Tighten the nuts to 25 Nm (18 ft. lbs.). 9. Install the engine front cover. 10. Install the oil pan. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot 41 kPa at 1,000 engine RPM (6 psig at 1,000 engine RPM) 124 kPa at 2,000 engine RPM (18 psig at 2,000 engine RPM) 165 kPa at 4,000 engine RPM (24 psig at 4,000 engine RPM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 4141 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing ^ Tools Required J 21867 Pressure Gage - J 42907 Oil Pressure Tester 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: ^ Oil diluted by water or glycol antifreeze ^ Foamy oil 6. Remove the oil filter and install the J 42907 . 7. Install the J 21867, or equivalent to the J 42907 . 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L33 VIN B) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N) . 10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: ^ Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection . ^ Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation . ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure relief valve ^ Excessive bearing clearance ^ Cracked, porous, or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation . ^ Broken valve lifters Repair as necessary. 11. If the oil pressure reading on the J 21867, or equivalent, is within specifications, inspect for the following conditions: ^ Plugged or incorrect oil filter and/or malfunctioning oil bypass valve ^ Malfunctioning oil pressure gage or sensor. Repair, as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair Oil Pressure Regulator Valve: Service and Repair Oil Filter Bypass Valve Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). 4. Remove the oil filter bypass valve (2). Installation Procedure 1. Install the oil filter bypass valve (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter adapter (1). ^ Tighten the oil filter adapter to 55 Nm (40 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Page 4145 3. Install the oil filter. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 4. Refill the engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4150 Intake Manifold: Specifications Intake Manifold Intake Manifold Bolts - First Pass in Sequence .................................................................................................................................... 5 Nm (44 inch lbs.) Intake Manifold Bolts - Final Pass in Sequence ................................................................................................................................. 10 Nm (89 inch lbs.) Throttle Body bolts Throttle Body Nuts ............................................................................................................................... .............................................. 10 Nm (89 inch lbs.) Throttle Body Studs ............................................. ................................................................................................................................ 6 Nm (53 inch lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4151 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure 1. Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. Remove the throttle body. 2. Remove the fuel injectors. 3. Disconnect the following electrical connectors: ^ Manifold absolute pressure (MAP) sensor (1) ^ Knock sensor (2) 4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the electrical harness aside. 6. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4152 7. Remove the positive crankcase ventilation (PCV) hose. 8. Remove the MAP sensor (1) from the intake manifold. 9. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following: 1. Remove the EVAP tube end from the solenoid (1). 2. Remove the EVAP tube end from the vapor pipe (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4153 10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold. 11. Loosen the intake manifold bolts. 12. Remove the intake manifold. 13. Remove the intake manifold gaskets (1) from the intake manifold. 14. Discard the old intake manifold gaskets. 15. If required, clean and inspect the intake manifold. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4154 1. Install NEW intake manifold gaskets (1) to the intake manifold. 2. Install the intake manifold. 3. Apply a 5 mm (0.20 inch) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the intake manifold bolts. 1. Tighten the bolts a first pass in sequence to 5 Nm (44 inch lbs.). 2. Tighten the bolts a final pass in sequence to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4155 5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2). 7. Important: Lightly coat the MAP sensor seal with clean engine oil before installing. Install the MAP sensor (1) to the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 4156 8. Install the PCV hose. 9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold. 10. Route the electrical harness into position over the engine. 11. Connect the knock sensor harness electrical connector to the intake manifold. 12. Connect the following electrical connectors. ^ MAP sensor (1) ^ Knock sensor (2) 13. Install the fuel injectors. 14. Install the throttle body. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement (4.8L, 5.3L, and 6.0L Engines) ^ Tools Required J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the engine flywheel. 2. Remove the crankshaft rear oil seal (1) from the rear cover. Installation Procedure Important: ^ The flywheel spacer (if applicable) must be removed prior to oil seal installation. ^ Do not lubricate the oil seal inside diameter (ID) or the crankshaft surface. ^ Do not reuse the crankshaft rear oil seal. 1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface. 2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface. 3. Install the J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts until snug. Do not overtighten. 5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore. 6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 4161 7. Align the oil seal into the tool (1). 8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 9. Remove the J 41479 . 10. Install the engine flywheel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement ^ Tools Required J 41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Remove the crankshaft oil seal (1) from the front cover. Installation Procedure Important: ^ Do not lubricate the oil seal sealing surface. ^ Do not reuse the crankshaft oil seal. 1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. 3. Install the crankshaft front oil seal onto the J 41478 guide. 4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J 41478 in order to install the oil seal into the cover bore. 1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 4165 3. Remove the J 41478 . 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. 2. Disconnect the spark plug wire at the spark plug. ^ Twist each plug wire boot 1/2 turn. ^ Pull only on the boot in order to remove the wire from the spark plug. 3. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. Loosen the spark plug 1 or 2 turns. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 4169 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (2). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (3). 14. Remove the valve spring (4). 15. Remove the valve stem oil seal and shim (1, 5). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 4170 1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (1, 5). 4. Install the valve spring (4). 5. Install the valve spring cap (3). 6. Compress the valve spring using the J 38606 . 7. Install the valve keys. ^ Use grease in order to hold the valve keys in place. ^ Make sure the keys seat properly in the groove of the valve stem. ^ Carefully release the valve spring pressure, making sure the valve keys stay in place. ^ Remove the J 38606 . ^ Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. 8. Remove the J 22794 from the spark plug port. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 4171 9. Notice: Refer to Fastener Notice in Service Precautions. Hand start the spark plug. ^ Tighten the spark plug to 15 Nm (11 ft. lbs.). 10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug. 12. Inspect the wires for proper installation: ^ Push sideways on each boot in order to check for proper installation. ^ Reinstall any loose boot. 13. Install the rocker arm. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level sensor to the oil pan. ^ Tighten the sensor to 13 Nm (115 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 4176 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 4186 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement ^ Tools Required J 8433 Two Jaw Puller - J 41816-2Crankshaft End Protector - J 41558 Crankshaft Sprocket Remover - J 41665 Crankshaft Balancer and Sprocket Installer Removal Procedure 1. Remove the oil pump. 2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 3. Remove the camshaft sprocket bolts. 4. Remove the camshaft sprocket and timing chain. 5. Use the J 8433, the J 41816-2 and the J 41558 in order to remove the crankshaft sprocket. 6. Remove the crankshaft sprocket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 4191 7. Remove the crankshaft sprocket key, if required. 8. If required, clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. 2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft. 3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 4192 4. Use the J 41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. 6. Important: o Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. ^ The sprocket teeth and timing chain must mesh. ^ The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position. Install the camshaft sprocket and timing chain. 7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the camshaft sprocket bolts. ^ Tighten the bolts to 35 Nm (26 ft. lbs.). 9. Install the oil pump. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Tighten the oil pan and oil pan-to-oil pan front cover bolts to ............................................................................................................... 25 Nm (18 ft. lbs.). Tighten the engine front cover bolts to ................................................................................................................................................... 25 Nm (18 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 4199 Timing Cover: Service and Repair Engine Front Cover Replacement ^ Tools Required J 41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the water pump. 3. Remove the oil pan-to-front cover bolts (1). 4. Remove the front cover bolts. 5. Remove the front cover and gasket. 6. Discard the front cover gasket. 7. If required, clean and inspect the engine front cover. Installation Procedure Important: ^ Do not reuse the crankshaft oil seal or front cover gasket. ^ Do not apply any type of sealant to the front cover gasket, unless specified. ^ The special tool in this procedure is used to properly center the front crankshaft front oil seal. ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ The crankshaft front oil seal MUST be centered in relation to the crankshaft. ^ An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 4200 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the front cover gasket and cover. 3. Install the front cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-front cover bolts (1) until snug. Do not over tighten. 5. Install J 41476 to the front cover. 6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the crankshaft balancer bolt until snug. Do not overtighten. 1. Tighten the oil pan to front cover bolts to 25 Nm (18 ft. lbs.). 2. Tighten the engine front cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J 41476 . 9. Install a NEW crankshaft front oil seal. 10. Install the water pump. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4207 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4208 Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4209 Step 6 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4225 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4231 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4232 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4233 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 4239 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1000 Ohms per ft Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 4243 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 4244 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(r) spark plug wires MUST be used only with the Melco(r) coils and bracket, like wise the Delphi(r) spark plug wires MUST be used only with Delphi(r) coils and bracket. The components are NOT interchangeable. 4. The Melco(r) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(r) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(r) (1) ignition coil is a square design. 7. The Delphi(r) (2) ignition coil is a round design. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 4245 8. The Melco(r) ignition coil bracket (1) is a square design. 9. The Delphi(r) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................................... 1.52 mm (0.060 in.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 4250 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ................................................... 15 Nm (11.0 lb. ft.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4251 Spark Plug: Application and ID SPARK PLUG TYPE AC Delco P/N ...................................................................................................................................... .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4252 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). An excessively wide electrode gap can prevent correct spark plug Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4253 operation. - Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4254 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4255 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder should read less than ............................................................................................................................................................ 690 kPa (100 psi). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4259 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 5 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts - First Pass ............................................................................................................ ....................................................... 15 Nm (11 ft. lbs.) Water Pump Bolts - Final Pass ...................... ............................................................................................................................................ 30 Nm (22 ft. lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4263 Water Pump: Locations Cooling System Component Views Auxiliary Water Pump - HP2 1 - Auxiliary Water Pump Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Diagrams > Auxiliary Water Pump (HP2) Auxiliary Water Pump (HP2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Diagrams > Auxiliary Water Pump (HP2) > Page 4266 Starter/generator Control Module Coolant Pump (HP2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement Water Pump: Service and Repair Auxiliary Water Pump Replacement Water Pump Replacement - Auxiliary Removal Procedure 1. Drain the cooling system. 2. Reposition the front heater inlet hose clamp (4) from the auxiliary water pump (1). 3. Remove the front heater inlet hose (6) from the auxiliary water pump (1). 4. Reposition the rear heater inlet hose clamp (2) from the auxiliary water pump (1). 5. Remove the rear heater inlet hose (3) from the auxiliary water pump (1). 6. Remove the heater outlet hose from the clip. 7. Disconnect the electrical connector (1) from the auxiliary water pump (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4269 8. Remove the nuts (4) from the auxiliary water pump bracket (1). 9. Remove the auxiliary water pump (1) from the vehicle. 10. Remove the clips (2) from the auxiliary water pump bracket (1). 11. Remove the auxiliary water pump (3) from the auxiliary water pump bracket (1). Installation Procedure 1. Install the auxiliary water pump (3) to the auxiliary water pump bracket (1). 2. Install the clips (2) to the auxiliary water pump bracket (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4270 3. Install the auxiliary water pump (1) to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the nuts (4) to the auxiliary water pump bracket (1). ^ Tighten the nuts to 9 Nm (80 inch lbs.). 5. Connect the electrical connector (1) to the auxiliary water pump (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4271 6. Install the heater outlet hose to the clip. 7. Install the rear heater inlet hose (3) to the auxiliary water pump (1). 8. Position the rear heater inlet hose clamp (2) to the auxiliary water pump (1). 9. Install the front heater inlet hose (6) to the auxiliary water pump (1). 10. Position the front heater inlet hose clamp (4) to the auxiliary water pump (1). 11. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4272 Water Pump: Service and Repair Water Pump Replacement Water Pump Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator hose clips. 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. If necessary, remove the fan blade. 10. Remove the accessory drive belt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4273 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4274 Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the water pump bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). 2. Tighten the bolts a final pass to 30 Nm (22 ft. lbs.). 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4275 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. 10. If necessary, install the fan blade. 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. 15. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4276 ^ Tighten the clamps to 4 Nm (35 inch lbs.). 18. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Hose Replacement Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Hose Replacement Coolant Air Bleed Hose Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Reposition the coolant air bleed hose clamp at the throttle body. 2. Remove the coolant air bleed hose from the throttle body. 3. Reposition the coolant air bleed hose clamp at the pipe. 4. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure 1. Install the coolant air bleed hose (1) to the pipe (2). 2. Position the coolant air bleed hose clamp at the pipe. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Hose Replacement > Page 4282 3. Install the coolant air bleed hose to the throttle body. 4. Position the coolant air bleed hose clamp at the throttle body. 5. Add engine coolant, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Hose Replacement > Page 4283 Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Pipe Assembly Replacement Coolant Air Bleed Pipe Assembly Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Remove the coolant air bleed pipe bolts/studs (1). 3. Remove the coolant air bleed pipe (2) with gaskets (3). 4. Remove the coolant air bleed pipe cover bolts (1) and covers (2). 5. Remove the gaskets from the coolant air bleed pipe and covers. 6. Discard the gaskets. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Hose Replacement > Page 4284 7. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure 1. Install the coolant air bleed hose (1) onto the pipe (2). 2. Important: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe. Install the gaskets onto the coolant air bleed pipe and covers. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Hose Replacement > Page 4285 3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the coolant air bleed pipe bolts/studs (1). ^ Tighten the bolts/studs to 12 Nm (106 inch lbs.). 5. Install the coolant air bleed pipe covers (2) and bolts (1). ^ Tighten the bolts to 12 Nm (106 inch lbs.). 6. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4290 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4291 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4292 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4293 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY AUTOMATIC WITH FRONT A/C With Engine Fan Driven cooling system ..................................................................................................................................... 15.2 quarts (14.4 liters) With Electric Cooling Fan system .............................................................................................................................................. 16.8 quarts (15.9 liters) MANUAL WITH FRONT A/C With Engine Fan Driven cooling system ..................................................................................................................................... 15.5 quarts (14.7 liters) With Electric Cooling Fan system .............................................................................................................................................. 17.0 quarts (16.1 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 4296 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp from the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 4300 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Locations Coolant Reservoir: Locations Cooling System Component Views 1 - Auxiliary Battery Relay (TP2) 2 - A/C Accumulator 3 - A/C Low Pressure Switch 4 - Inner Wheel Well 5 - Coolant Level Switch Connector Diesel and 8.1L 6 - Mass Air Flow (MAF) Sensor 7 - Air Cleaner Assembly 8 - Engine Coolant Recovery Reservoir 9 - Auxiliary Battery Relay Electrical Connector (TP2) 10 - Battery Right (TP2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4306 Coolant Reservoir: Service and Repair Surge Tank Replacement Surge Tank Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the surge tank overflow hose from the surge tank. 4. Disconnect the coolant level sensor electrical connector (3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4307 5. Reposition the surge tank inlet and outlet hose clamps. 6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank. 7. Reposition the surge tank inlet hose clamp from the surge tank. 8. Remove the surge tank inlet hose (1) from the surge tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4308 9. Reposition the surge tank outlet hose clamp from the surge tank. 10. Remove the surge tank outlet hose (2) from the surge tank. 11. Remove the bolt from the surge tank. 12. Remove the nut from the surge tank. 13. Remove the surge tank. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4309 1. Install the surge tank. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt to the surge tank. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the nut to the surge tank. ^ Tighten the nut to 9 Nm (80 inch lbs.). 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp to the surge tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4310 6. Install the surge tank inlet hose (1) to the surge tank. 7. Position the surge tank inlet hose clamp to the surge tank. 8. Connect the coolant level sensor electrical connector (3). 9. Install the surge tank overflow hose. 10. Install the air cleaner assembly. 11. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 Radiator Cooling Fan Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Radiator Cooling Fan Motor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Cooling Fan Motor Replacement - Electric Radiator Cooling Fan Motor: Service and Repair Cooling Fan Motor Replacement - Electric Cooling Fan Motor Replacement - Electric Removal Procedure 1. Remove the cooling blade(s). 2. Remove the cooling fan motor bolts. 3. Remove the cooling fan motor(s). Installation Procedure 1. Install the cooling fan motor(s). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the cooling fan motor bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 3. Install the cooling fan blade(s). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Cooling Fan Motor Replacement - Electric > Page 4462 Radiator Cooling Fan Motor: Service and Repair Cooling Fan Replacement - Electric Cooling Fan Replacement - Electric Removal Procedure 1. Remove the cooling fan and shroud. 2. Remove the cooling fan blade retainers. 3. Remove the cooling fan blades. Installation Procedure Important: The electric cooling fan assembly uses a 5-blade fan and a 7-blade fan, it does not matter which side the fan blades are installed on. DO NOT install two 5-blade assemblies or two 7-blade assemblies, as this would cause a noise issue. 1. Install the cooling fan blades. 2. Install the cooling fan blade retainers. 3. Install the cooling fan and shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 4466 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 4467 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 Radiator Cooling Fan Motor Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Fan Replacement (Gasoline) ^ Tools Required J 46406 Fan Clutch Remover and Installer Removal Procedure 1. Remove the upper fan shroud. 2. Install the J 46406 to the fan clutch. 3. Remove the fan hub nut from the water pump in a counterclockwise rotation. 4. Remove the fan clutch bolts from the rear of the fan blade. 5. Separate the fan clutch from the fan blade. Installation Procedure Caution: Do not use or attempt to repair a damaged cooling fan assembly. Replace damaged fans with new assemblies. An unbalanced cooling fan could fly apart causing personal injury and property damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 4543 1. Install the fan clutch onto the fan blade. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the fan clutch bolts ^ Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Install the fan assembly. 4. Install the J 46406 to the fan clutch. ^ Tighten the nut clockwise to 56 Nm (41 ft. lbs.). 5. Install the upper fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair Fan Clutch: Service and Repair Fan Clutch Replacement (Gasoline) ^ Tools Required J 46406 Fan Clutch Remover and Installer Removal Procedure 1. Remove the upper fan shroud. 2. Install the J 46406 to the fan clutch. 3. Remove the fan hub nut from the water pump in a counterclockwise rotation. 4. Remove the fan clutch bolts from the rear of the fan blade. 5. Separate the fan clutch from the fan blade. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Page 4547 1. Install the fan clutch bolts from the rear of the fan blade. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the fan clutch bolts. ^ Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Install the fan assembly. 4. Install the J 46406 to the fan clutch. ^ Tighten the nut clockwise to 56 Nm (41 ft. lbs.). 5. Install the upper fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4557 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4558 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4559 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4560 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4566 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4567 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4568 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4569 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4570 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4571 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4572 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4573 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement Fan Shroud: Service and Repair Cooling Fan and Shroud Replacement Cooling Fan and Shroud Replacement Removal Procedure 1. Disengage the radiator inlet hose clip (2) at the fan shroud. 2. Reposition the surge tank inlet hose clamp at the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Disconnect the electrical connectors from the cooling fans. 5. Remove the clip attaching the wiring harness to the shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4578 6. If necessary, open the engine oil cooler line clip and remove the cooler lines from the clip. 7. Remove the cooling fan shroud bolts. 8. Remove the cooling fan and shroud. Installation Procedure 1. Important: Insert the three lower tabs into the radiator support flange. Keeping the shroud parallel to the radiator will ensure the correct installation of the lower tabs. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4579 Install the cooling fan and shroud. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the cooling fan shroud bolts. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 3. If equipped, install the cooler lines to the clip and close the clip. 4. Connect the electrical connectors to the cooling fans. 5. Install the clip attaching the wiring harness to the shroud. 6. Install the surge tank inlet hose to the radiator. 7. Reposition the surge tank inlet hose clamp at the radiator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4580 8. Engage the radiator inlet hose clip (2) at the fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4581 Fan Shroud: Service and Repair Fan Shroud Replacement - Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the cooling fan. 2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud. 3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator. Installation Procedure 1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down. 2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud. 3. Install the cooling fan. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4582 Fan Shroud: Service and Repair Fan Shroud Replacement - Upper Automatic Transmission Fan Shroud Replacement - Upper (Automatic Transmission - Gasoline) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. Remove the A/C line retainer from the fan shroud. 5. Remove the engine harness clip from the powertrain control module (PCM) cover. 6. Remove the transmission control module (TCM) cover bolts. 7. Remove TCM cover from the fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4583 8. Loosen the TCM electrical connector bolts. 9. Disconnect the TCM electrical connectors (1). 10. Remove the TCM and cover. 11. Remove the fan shroud retainers. 12. Remove the fan shroud bolts 13. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4584 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the fan shroud retainers. 4. Connect the TCM electrical connectors (1). 5. Install the TCM and cover. 6. Tighten the TCM electrical connector bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 7. Install the TCM cover to the fan shroud. 8. Install the TCM cover bolts. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4585 9. Install the engine harness clip to the PCM cover. 10. Install the A/C line retainer to the fan shroud. 11. Install the air cleaner outlet duct. 12. Tighten the air cleaner outlet duct clamp at the throttle body. ^ Tighten the clamp to 4 Nm (35 inch lbs.). 13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. ^ Tighten the clamp to 4 Nm (35 inch lbs.). Manual Transmission Fan Shroud Replacement - Upper (Manual Transmission - Gasoline) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4586 6. Remove the fan shroud retainers. 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 4587 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. ^ Tighten the clamp to 4 Nm (35 inch lbs.). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. ^ Tighten the clamp to 4 Nm (35 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4592 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4593 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) Heater Core: Service and Repair Heater Core (Visteon) HEATER CORE REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (1) from the HVAC module assembly (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) > Page 4596 INSTALLATION PROCEDURE 1. Install the heater core (1) to the HVAC module assembly (2). 2. Install the heater core cowl gasket (1) to the HVAC module assembly (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) > Page 4597 Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) > Page 4598 Heater Core: Service and Repair Heater Core (Delphi) HEATER CORE REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) > Page 4599 1. Install the heater core (2) to the HVAC module assembly (3). 2. Install the heater core cowl gasket (1) to the heater core (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) > Page 4600 Heater Core: Service and Repair Heater Core (Heat Only) HEATER CORE REPLACEMENT (HEAT ONLY) REMOVAL PROCEDURE 1. Remove the heater/vent module. 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE 1. Install the heater core. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core (Visteon) > Page 4601 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the heater/vent module. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the inlet heater hose from the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4606 6. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4607 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4608 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4613 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4614 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Radiator Air Baffle and Deflector Replacement - Side Radiator: Service and Repair Radiator Air Baffle and Deflector Replacement - Side Radiator Air Baffle and Deflector Replacement - Side Removal Procedure 1. Remove the radiator. 2. Remove the radiator air baffle retainers. 3. Remove the radiator air baffles. Installation Procedure 1. Install the radiator air baffles. 2. Install the radiator air baffle retainers. 3. Install the radiator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Radiator Air Baffle and Deflector Replacement - Side > Page 4617 Radiator: Service and Repair Radiator Air Baffle and Deflector Replacement - Upper Radiator Air Baffle and Deflector Replacement - Upper Removal Procedure 1. Remove the radiator air upper baffle retainers. 2. Remove the radiator air upper baffle. Installation Procedure 1. Install the radiator air upper baffle. 2. Install the radiator air upper baffle retainers. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Radiator Air Baffle and Deflector Replacement - Side > Page 4618 Radiator: Service and Repair Radiator Replacement Radiator Replacement (4.3, 4.8, 5.3, and 6.0L) Removal Procedure 1. Remove the cooling fan and shroud. 2. Remove the radiator outlet hose for the 4.3L engine, or the 4.8L, 5.3L and 6.0L engines. 3. Disconnect the engine oil cooler lines from the radiator, if necessary . 4. Disconnect the transmission oil cooler lines from the radiator, if necessary. 5. Remove the radiator bolts. 6. Remove the radiator. Installation Procedure 1. Install the radiator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the radiator bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Connect the transmission oil cooler lines to the radiator, if necessary. 4. Connect the engine oil cooler lines to the radiator, if necessary. 5. Install the cooling fan and shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Pressure Cap Testing Radiator Cap: Testing and Inspection Pressure Cap Testing Pressure Cap Testing ^ Tools required J 24460-01 Cooling System Pressure Tester - J 42401 Radiator Cap / Surge Tank Test Adapter Pressure Cap Testing 1. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Pressure Cap Testing > Page 4623 Radiator Cap: Testing and Inspection Pressure Cap Testing - Starter/Generator Control Module Pressure Cap Testing - Starter/Generator Control Module ^ Tools Required J 24460-01 Cooling System Pressure Tester - J 46143 Cooling System Adapter 1. Caution: To avoid being burned, do not remove the starter/generator control module (SGCM) cap while the SGCM is hot. The cooling system will release scalding fluid and steam under pressure if the SGCM cap is removed while the SGCM is still hot. Follow the steps below in order to remove the starter/generator control module (SGCM) coolant tank cap. 1. Slowly rotate the cap counterclockwise. 2. Stop rotating and allow the hissing to stop. 3. After all the hissing stops, continue turning counterclockwise in order to remove the cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with the J 46143 in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Hose Replacement - Inlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet hose. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator inlet hose clips. 7. Reposition the inlet hose clamp at the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Remove the inlet hose (1) from the radiator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 4628 10. Reposition the inlet hose clamp at the water pump. 11. Remove the inlet hose from the water pump. Installation Procedure 1. Install the inlet hose to the water pump. 2. Position the inlet hose clamp at the water pump. 3. Install the inlet hose (1) to the radiator. 4. Position the inlet hose clamp at the radiator. 5. Install the inlet hose clip to the fan shroud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 4629 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield. 8. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. 10. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor ^ Tighten the clamps to 4 Nm (35 inch lbs.). 11. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 4630 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the outlet hose clamp at the water pump. 6. Remove the outlet hose from the water pump. 7. Reposition the outlet hose clamp at the radiator. 8. Remove the outlet hose (6) from the radiator. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 4631 1. Install the outlet hose (6) to the radiator. 2. Position the outlet hose clamp at the radiator. 3. Install the outlet hose to the water pump. 4. Position the outlet hose clamp at the water pump. 5. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor ^ Tighten the clamps to 4 Nm (35 inch lbs.). 8. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Radiator Cooling Fan Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Location View Application Table Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 4710 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 4711 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 Radiator Cooling Fan Motor Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4794 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4795 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4796 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4797 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4803 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4804 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4805 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4806 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4807 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4808 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4809 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4810 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Thermostat Housing Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure Important: The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly. 1. Remove the radiator outlet hose. 2. Remove the water pump inlet bolts. 3. Remove the water pump inlet and thermostat from the water pump. Installation Procedure 1. Install the thermostat and thermostat housing to the water pump. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat housing bolts. ^ Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the radiator outlet hose. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts - First Pass ............................................................................................................ ....................................................... 15 Nm (11 ft. lbs.) Water Pump Bolts - Final Pass ...................... ............................................................................................................................................ 30 Nm (22 ft. lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4817 Water Pump: Locations Cooling System Component Views Auxiliary Water Pump - HP2 1 - Auxiliary Water Pump Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Diagrams > Auxiliary Water Pump (HP2) Auxiliary Water Pump (HP2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Diagrams > Auxiliary Water Pump (HP2) > Page 4820 Starter/generator Control Module Coolant Pump (HP2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement Water Pump: Service and Repair Auxiliary Water Pump Replacement Water Pump Replacement - Auxiliary Removal Procedure 1. Drain the cooling system. 2. Reposition the front heater inlet hose clamp (4) from the auxiliary water pump (1). 3. Remove the front heater inlet hose (6) from the auxiliary water pump (1). 4. Reposition the rear heater inlet hose clamp (2) from the auxiliary water pump (1). 5. Remove the rear heater inlet hose (3) from the auxiliary water pump (1). 6. Remove the heater outlet hose from the clip. 7. Disconnect the electrical connector (1) from the auxiliary water pump (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4823 8. Remove the nuts (4) from the auxiliary water pump bracket (1). 9. Remove the auxiliary water pump (1) from the vehicle. 10. Remove the clips (2) from the auxiliary water pump bracket (1). 11. Remove the auxiliary water pump (3) from the auxiliary water pump bracket (1). Installation Procedure 1. Install the auxiliary water pump (3) to the auxiliary water pump bracket (1). 2. Install the clips (2) to the auxiliary water pump bracket (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4824 3. Install the auxiliary water pump (1) to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the nuts (4) to the auxiliary water pump bracket (1). ^ Tighten the nuts to 9 Nm (80 inch lbs.). 5. Connect the electrical connector (1) to the auxiliary water pump (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4825 6. Install the heater outlet hose to the clip. 7. Install the rear heater inlet hose (3) to the auxiliary water pump (1). 8. Position the rear heater inlet hose clamp (2) to the auxiliary water pump (1). 9. Install the front heater inlet hose (6) to the auxiliary water pump (1). 10. Position the front heater inlet hose clamp (4) to the auxiliary water pump (1). 11. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4826 Water Pump: Service and Repair Water Pump Replacement Water Pump Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator hose clips. 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. If necessary, remove the fan blade. 10. Remove the accessory drive belt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4827 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4828 Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the water pump bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). 2. Tighten the bolts a final pass to 30 Nm (22 ft. lbs.). 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4829 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. 10. If necessary, install the fan blade. 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. 15. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Auxiliary Water Pump Replacement > Page 4830 ^ Tighten the clamps to 4 Nm (35 inch lbs.). 18. Fill the cooling system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4836 Catalytic Converter: Service and Repair Catalytic Converter Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped, unclip the oxygen sensor connection from the floor reinforcement. 3. Disconnect the oxygen sensor electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4837 4. Remove the oxygen sensor clips from the frame. 5. Disconnect the connector position assurance (CPA) retainers. 6. Disconnect the oxygen sensor electrical connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4838 7. Unclip the oxygen sensors electrical connectors from the following: - Hose clip - Transmission crossmember 8. Disconnect the CPA retainers. 9. Disconnect the oxygen sensor electrical connectors (1, 2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4839 10. Remove the left exhaust manifold pipe nuts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4840 11. Remove the right exhaust manifold pipe nuts. 12. Remove the exhaust muffler nuts. 13. Remove the catalytic converter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4841 14. If necessary, remove the oxygen sensors. Installation Procedure Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4842 1. If necessary, install the oxygen sensors. 1.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 1.2. Install the oxygen sensors. Tighten Tighten the sensors to 42 Nm (31 lb ft). 2. Install the catalytic convertor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4843 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4844 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the exhaust manifold pipe nuts. Tighten Tighten the nuts to 50 Nm (39 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4845 7. Install the exhaust muffler nuts. Tighten Tighten the nuts to 40 Nm (30 lb ft). 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: - Hose clip - Transmission crossmember Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4846 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4847 14. Connect the oxygen sensor electrical connector. 15. If equipped, clip the oxygen sensor connection to the floor reinforcement. 16. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold - Left Tighten the bolts a first pass ................................................................................................................ ................................................... 15 Nm (11 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass ............................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Exhaust Manifold - Right Tighten the bolts a first pass ................................................................................................................ ................................................... 15 Nm (11 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass ............................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Removal - Left Exhaust Manifold: Service and Repair Exhaust Manifold Removal - Left Exhaust Manifold Replacement - Left (4.8L, 5.3L, and 6.0L Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the spark plugs. 5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket. 7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary. 8. Clean and inspect the exhaust manifold. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Removal - Left > Page 4853 1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten the bolts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. Important: o Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. ^ The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt. 3. Install the exhaust manifold, NEW gasket and bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head. 5. Install the spark plugs. 6. Raise the vehicle. 7. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Removal - Left > Page 4854 Exhaust Manifold: Service and Repair Exhaust Manifold Removal - Right Exhaust Manifold Replacement - Right (4.8L, 5.3L, and 6.0L Engines) 1. Raise and suitably support the vehicle. 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the spark plugs. 5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket. 7. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary. 8. Clean and inspect the exhaust manifold. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Removal - Left > Page 4855 1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten the bolts to 9 Nm (80 inch lbs.). 2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. Important: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. ^ The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt. 3. Install the exhaust manifold, NEW gasket and bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head. 5. Install the spark plugs. 6. Raise the vehicle. 7. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement Exhaust Pipe: Service and Repair Exhaust Manifold Pipe Replacement Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a suitable transmission jack. 3. Remove the transmission mount to transmission support nuts. 4. Raise the transmission off of the transmission support. 5. Remove the transmission support crossmember bolts. 6. Remove the transmission support crossmember. 7. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. 8. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Remove the clip around the engine harness and the oxygen sensor pigtail. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the oxygen sensor electrical connector. 4. Remove the oxygen sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4860 9. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe nuts. 10. Using the transmission jack, lower the transmission slightly. 11. If equipped with the 6.6L engine, remove the exhaust muffler nuts. 12. If equipped with a 6.6L engine, loosen the exhaust pipe clamp. 13. Slide the exhaust pipe clamp up onto the exhaust pipe adapter. 14. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe. 15. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. 16. Discard the exhaust manifold pipe seal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4861 17. If equipped with a 6.0L engine, with RPO Y91, remove the exhaust manifold pipe. 18. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. 19. Discard the exhaust manifold pipe seal. 20. If equipped with a 6.6L engine, remove the exhaust manifold pipe. 21. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. Installation Procedure 1. If equipped with a 6.6L engine, install the exhaust manifold pipe. 2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 3. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket. 4. If equipped with a 6.0L engine, with RPO Y91, install a new exhaust manifold pipe seal to the exhaust manifold pipe. 5. Install the exhaust manifold pipe. 6. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 7. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4862 8. If equipped with a 6.0L or 8.1L engine, install a new exhaust manifold pipe seal to the exhaust manifold pipe. 9. Install the exhaust manifold pipe. 10. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 11. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket. 12. If equipped with the 6.6L engine, install the exhaust muffler nuts until snug. 13. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Notice: Refer to Fastener Notice in Service Precautions. 14. Tighten the exhaust pipe clamp and muffler nuts. ^ Tighten the clamp to 40 Nm (30 ft. lbs.). ^ Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4863 15. If equipped with a 6.0L or 8.1L engine, install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 16. Using the transmission jack, raise the transmission. 17. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was replaced perform the following: 1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. 2. Install the old oxygen sensor. Tighten the sensor to 42 Nm (31 ft. lbs.). 18. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was not replaced perform the following: 0. Connect the oxygen sensor electrical connector. 1. Connect the CPA retainer. 2. Install the clip around the engine harness and the oxygen sensor pigtail. 19. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. 20. Install the transmission support crossmember. 21. Install the transmission support crossmember bolts. Tighten the bolts to 95 Nm (70 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4864 22. Lower the transmission onto the transmission support. 23. Install the transmission mount to transmission support nuts. Tighten the bolts to 40 Nm (30 ft. lbs.). 24. Remove the support from the transmission. 25. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4865 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement Left Exhaust Pipe Replacement - Left (6.6L (LLY) Engine) Removal Procedure 1. Remove the right wheelhouse panel. 2. Remove the exhaust heat shield nuts (2) and heat shield (3) from the dash panel. 3. Remove the left exhaust pipe heat shield bolts. 4. Remove the heat shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4866 5. Remove the exhaust pipe bolts in the proper sequence. 6. Remove the exhaust pipe and gaskets. 7. Discard the gaskets. Installation Procedure 1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward. 2. Loosely install the bolts. 3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4867 4. Loosely install the bolts. 5. Tighten the exhaust pipe bolts in the sequence shown. Tighten the bolts to 53 Nm (39 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the exhaust pipe heat shield bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 7. Install the left side exhaust heat shield (3) at the dash panel. 8. Install the heat shield nuts (2). Tighten the nuts to 9 Nm (80 inch lbs.). 9. Install the right wheelhouse panel. Right Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4868 Exhaust Pipe Replacement - Right (6.6L (LLY) Engine) Removal Procedure 1. Remove the turbocharger exhaust pipe. 2. Remove the exhaust pipe bolts in the proper sequence. 3. Remove the exhaust pipe, bracket and gaskets. 4. Discard the gaskets. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4869 1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward. 2. Loosely install the bolts. 3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward. 4. Loosely install the bolts. 5. Tighten the exhaust pipe bolts in the proper sequence. Tighten the bolts to 53 Nm (39 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the turbocharger exhaust pipe. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4870 Exhaust Pipe: Service and Repair Turbocharger Exhaust Pipe Replacement Turbocharger Exhaust Pipe Replacement (6.6L (LLY) Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Loosen the exhaust manifold pipe clamp. 3. Slide the exhaust pipe clamp up onto the exhaust pipe. 4. Remove the exhaust muffler nuts. 5. Slide the exhaust manifold pipe hanger out from the insulator. 6. Remove the exhaust manifold pipe. 7. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4871 8. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission. 9. Lower the vehicle. 10. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2). 11. Remove the intake manifold cover. 12. Remove the turbocharger upper heat shield bolts. 13. Remove the turbocharger upper heat shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4872 14. Remove the exhaust outlet heat shield bolts. 15. Remove the exhaust outlet heat shield. 16. Remove the exhaust outlet to right exhaust pipe bracket bolt. 17. Loosen the exhaust outlet pipe clamp. 18. Remove the exhaust outlet pipe. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4873 1. Install the exhaust outlet pipe. 2. Tighten the exhaust outlet pipe clamp. Tighten the clamp to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust outlet to right exhaust pipe bracket bolt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4874 Tighten the bolt to 34 Nm (25 ft. lbs.). 4. Install the exhaust outlet heat shield. 5. Install the exhaust outlet heat shield bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 6. Install the turbocharger upper heat shield. 7. Install the turbocharger upper heat shield bolts. Tighten the bolts to 9 Nm (80 inch lbs.). 8. Install the intake manifold cover. 9. Remove the hood hinge bolts (1) from the service position (2) and position the hood in the normal position. Tighten the bolts to 25 Nm (18 ft. lbs.). 10. Raise the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 4875 11. If equipped with an automatic transmission, position the transmission fluid fill tube to the studs. 12. Install the transmission fluid fill tube to bellhousing nuts. Tighten the nuts to 18 Nm (13 ft. lbs.). 13. Install the exhaust manifold pipe. 14. Slide the exhaust manifold pipe hanger into the insulator. 15. Install the exhaust muffler nuts until snug. 16. Slide the exhaust pipe clamp down onto the exhaust pipe. 17. Tighten the exhaust manifold pipe clamp. Tighten the clamp and nuts to 40 Nm (30 ft. lbs.). 18. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger Exhaust Pipe/Muffler Hanger: Service and Repair Hanger Exhaust Hanger Replacement (6.6L Engine with RPO YF2) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust muffler hanger nuts. 3. Remove the hanger from the hanger insulator. Installation Procedure 1. Install the hanger into the hanger insulator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust muffler hanger nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 3. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 4880 Exhaust Pipe/Muffler Hanger: Service and Repair Hanger Bracket Exhaust Hanger Mounting Bracket Replacement (6.0L, 6.6L, and 8.1L Engines) Removal Procedure 1. Remove the exhaust manifold pipe. 2. Remove the catalytic converter. 3. If equipped with a 4L60-E automatic transmission, remove the exhaust pipe hanger bracket bolts. 4. If equipped with a 6.0L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts. 5. If equipped with a 6.0L, or 8.1L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 4881 6. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the transmission bolts. 7. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the exhaust pipe hanger bracket bolts. 8. If equipped with a 6.6L or 8.1L engine and a Allison transmission, remove the exhaust pipe hanger bracket bolts. 9. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, remove the exhaust pipe hanger bracket bolts. 10. Remove the exhaust manifold pipe bracket. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 4882 1. Install the exhaust manifold pipe bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 3. If equipped with a 6.6L or 8.1L engine and a Allison transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 4. If equipped with a 6.0L engine and a 5-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 5. If equipped with a 6.0L engine and a 5-speed manual transmission, install the transmission bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 4883 6. If equipped with a 6.0L or 8.1L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 7. If equipped with a 6.0L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 8. If equipped with a 4L60-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 17 Nm (13 ft. lbs.). 9. Install the catalytic converter. 10. Install the exhaust manifold pipe. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: Customer Interest Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4892 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4893 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4894 Lower the vehicle. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4895 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: All Technical Service Bulletins Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4901 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4902 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4903 Lower the vehicle. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4904 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Removal Procedure 1. Remove the exhaust muffler. 2. Remove the spare tire hoist. 3. If equipped with a 6 1/2 ft. box, remove the exhaust heat shield bolts. 4. Remove the exhaust heat shield. 5. If equipped with a 8 ft. box, remove the exhaust heat shield bolts. 6. Remove the exhaust heat shield. Installation Procedure 1. if equipped with a 8 ft. box, install the exhaust heat shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement > Page 4907 3. if equipped with a 6 1/2 ft. box, install the exhaust heat shield. 4. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). 5. Install the spare tire hoist. 6. Install the exhaust muffler. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement > Page 4908 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust heat shield nuts. 3. Remove the exhaust heat shield (1, 3) from the dash panel studs. 4. If removing the heat shield (3), remove the shield out thru the passenger side wheelwell. Installation Procedure 1. If installing the heat shield (3), install the shield thru the passenger side wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust heat shield nuts. Tighten the nuts to 9 Nm (80 inch lbs.). 4. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement > Page 4909 Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the exhaust manifold pipe, if necessary. 2. Remove the catalytic converter, if necessary. 3. Remove the exhaust front heat shield nuts. 4. Remove the exhaust front heat shield from the studs. 5. If vehicle is a regular cab pick-up truck, remove the exhaust heat shield nuts. 6. Remove the exhaust front heat shield (1) and/or the exhaust heat shield (2) from the studs. 7. If vehicle is a extended cab pick-up truck, remove the exhaust heat shield nuts. 8. Remove the exhaust heat shield (1, 2) from the studs. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement > Page 4910 9. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts. 10. Remove the exhaust heat shields from the studs. Installation Procedure 1. If vehicle is a crew cab pick-up truck, install the exhaust heat shields to the studs. 2. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs. 4. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement > Page 4911 5. If vehicle is a regular cab pick-up truck, install the exhaust front heat shield (1) and/or the exhaust heat shield (2) to the studs. 6. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 7. Install the exhaust front heat shield to the studs. 8. Install the exhaust front heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 9. Install the catalytic converter, if necessary. 10. Install the exhaust manifold pipe, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust muffler nuts. 3. Apply lubricant to the exhaust insulators in order to aid in removal. 4. Remove the muffler brackets from the insulators. 5. Remove the exhaust muffler. Installation Procedure 1. Apply lubricant to the exhaust insulators in order to aid in installation. 2. Install the muffler to the insulators. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 4915 3. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Remove the clip from around the engine harness and the oxygen sensor pigtail. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the forward oxygen sensor electrical connector. 3. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Unclip the oxygen sensor electrical connector from the hose clip. 2. Disconnect the CPA retainer. 3. Disconnect the oxygen sensor electrical connector (1). 4. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Disconnect the CPA retainer. 2. Disconnect the oxygen sensor electrical connector (1). 5. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4920 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts. 7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts. 8. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts. 9. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Remove the left exhaust manifold pipe nuts. 2. Remove the exhaust hanger mounting bracket bolts. 10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 11. Remove the exhaust manifold pipe seal(s). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4921 1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 3. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Install the exhaust hanger mounting bracket bolts. 2. Install the left exhaust manifold pipe nuts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). ^ Tighten the nuts to 50 Nm (39 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. If equipped with a 6.0L or 8.1L engine, install the right exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 5. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the right exhaust manifold pipe nuts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4922 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the left exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 3. Clip the oxygen sensor electrical connector to the hose clip. 10. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4923 1. Connect the forward oxygen sensor electrical connector. 2. Connect the CPA retainer. 3. Install the clip around the engine harness and the oxygen sensor pigtail. 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module (BCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Body Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Splice Pack - SP205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Splice Pack - SP207 (Without RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Splice Pack - SP207 (With RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Body Control Module: Electrical Diagrams Door Control Module Diagrams Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Body Control System Diagrams Body Control System Schematics Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Power, Ground, and Serial Data Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Interior Lights and Interior Lights Dimming References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Headlights and Exterior Lights References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Controlled/Monitored Subsystem References - 1 of 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Controlled/Monitored Subsystem References - 2 of 2 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5025 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the Body Control Module (BCM) fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the Powertrain Control Module (PCM). If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5026 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5029 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up See: Computers and Control Systems/Information Bus/Testing and Inspection/Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with Class 2 Device - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with High Speed GMLAN Device - Power Mode Mismatch See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Retained Accessory Power (RAP) On After Time-Out - Retained Accessory Power (RAP) Inoperative See: Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5030 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5031 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 5032 Body Control Module: Service and Repair BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 5033 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 5042 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 5048 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 5053 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 5054 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 5055 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 5060 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 5061 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 5062 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 5067 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 5077 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 5082 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 5083 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 5084 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 5089 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 5090 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 5091 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5096 Powertrain Control Module (PCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Engine Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Powertrain Control Module (PCM) C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Powertrain Control Module (PCM) C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Powertrain Control Module (PCM) C2 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Powertrain Control Module (PCM) C2 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Powertrain Control Module (PCM) C2 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 5177 - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 5178 Engine Control Module: Description and Operation Throttle Actuator Control (TAC) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 5179 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5180 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NOS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5181 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: - Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5182 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5183 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary Fuel Pump Relay: Locations Primary Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 5189 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 5190 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 5191 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 5192 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 5193 Fuel Pump Relay - Secondary (Except RPO Code NQZ) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Fuel Pump Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5271 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5272 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5273 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5274 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5275 Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test (Non-HP2) Battery Inspection/Test (HP2) in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5276 Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5277 Step 8 - Step 17 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5278 Step 18 - Step 26 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 5279 Step 27 - Step 31 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5285 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5286 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5287 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5288 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5289 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5366 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5367 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Current Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5446 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5447 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission Clutch Switch: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 5452 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 5453 Clutch Switch: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 5454 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 5455 Clutch Switch: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 Manual Transmission > Page 5456 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5465 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5466 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5467 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5468 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5474 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5475 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5476 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5477 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Fluid Pump: All Technical Service Bulletins A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 5483 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 5484 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 5485 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 5491 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 5492 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 5493 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 5494 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 5495 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 5496 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 5497 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5573 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5576 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5577 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5581 Fuel Level Sensor: Application and ID FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5582 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement 2 FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 5585 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 5586 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 5587 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT (4.8L, 5.3L, AND 6.0L ENGINES) REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5591 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5592 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5593 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5597 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5598 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5599 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5676 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5677 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5678 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5682 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5683 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5684 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 5691 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors (HO2S) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Oxygen Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5770 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5771 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5772 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5773 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5774 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5775 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5776 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5854 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5855 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5858 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5861 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5864 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5865 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5866 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5867 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5868 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5869 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5874 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5875 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5876 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5877 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5878 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5955 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5956 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6107 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6108 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6184 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 6191 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 3. Lower the hush and knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Console. 4. Remove the steering column trim covers. 5. With the key installed, turn the key to the RUN position. 6. Install an allen wrench into the hole on top of the lock cylinder housing. Push down on the allen wrench to release the tab on the lock cylinder inside the lock cylinder housing. 7. Slide the lock cylinder out of the lock cylinder housing. Installation Procedure 1. Install the key into the lock cylinder. 2. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 6192 Important: The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN. 3. Align the lock cylinder and install into the lock cylinder housing. 4. Install the steering column trim covers. 5. Install the hush and knee bolster. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 7. Connect the negative battery cable. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 6193 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the ignition switch. 3. Remove the turn signal cancel cam. 4. Remove the park lock cable from the lock cylinder housing. 5. Remove 3 TORX(r) screws. 6. Remove the lock cylinder housing from the steering column. Installation Procedure 1. Install 3 TORX screws into the lock cylinder housing. ^ Tighten the TORX screws to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the turn signal cancel cam. 3. Install the park lock cable into the lock cylinder housing. 4. Install the ignition switch. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 6270 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 6271 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 6272 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6279 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6280 Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6281 Step 6 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6297 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6303 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 6304 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 6305 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 6311 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1000 Ohms per ft Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 6315 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 6316 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(r) spark plug wires MUST be used only with the Melco(r) coils and bracket, like wise the Delphi(r) spark plug wires MUST be used only with Delphi(r) coils and bracket. The components are NOT interchangeable. 4. The Melco(r) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(r) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(r) (1) ignition coil is a square design. 7. The Delphi(r) (2) ignition coil is a round design. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 6317 8. The Melco(r) ignition coil bracket (1) is a square design. 9. The Delphi(r) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................................... 1.52 mm (0.060 in.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 6322 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ................................................... 15 Nm (11.0 lb. ft.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 6323 Spark Plug: Application and ID SPARK PLUG TYPE AC Delco P/N ...................................................................................................................................... .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 6324 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). An excessively wide electrode gap can prevent correct spark plug Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 6325 operation. - Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 6326 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 6327 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder should read less than ............................................................................................................................................................ 690 kPa (100 psi). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 6331 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 5 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6336 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6337 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6338 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6339 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6340 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6417 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6418 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 6422 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 6423 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 6424 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Current Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module (BCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Body Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Splice Pack - SP205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Splice Pack - SP207 (Without RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 Splice Pack - SP207 (With RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 Body Control Module: Electrical Diagrams Door Control Module Diagrams Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Body Control System Diagrams Body Control System Schematics Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Power, Ground, and Serial Data Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Interior Lights and Interior Lights Dimming References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 Headlights and Exterior Lights References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 Controlled/Monitored Subsystem References - 1 of 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Controlled/Monitored Subsystem References - 2 of 2 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6526 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the Body Control Module (BCM) fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the Powertrain Control Module (PCM). If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6527 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6530 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up See: Information Bus/Testing and Inspection/Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device See: Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with Class 2 Device - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with High Speed GMLAN Device - Power Mode Mismatch See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Retained Accessory Power (RAP) On After Time-Out - Retained Accessory Power (RAP) Inoperative See: Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6531 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6532 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6533 Body Control Module: Service and Repair BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6534 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6610 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6611 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission Clutch Switch: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 6616 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 6617 Clutch Switch: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 6618 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 6619 Clutch Switch: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 6620 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6629 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6630 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6631 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6632 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6638 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6639 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6640 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6641 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 08-08-63-003 > Nov > 08 > Body - Replacement Fender Hood Hinge Hole Too Large Hood Hinge: All Technical Service Bulletins Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 6652 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 6653 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 6654 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 6655 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 6731 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6734 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6735 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 Data Link Connector: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Data Link Connector (DLC) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 6812 Data Link Connector: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via 2 splice packs: SP205-Located behind the instrument panel (I/P) near the headlamp switch connector. - SP207-Located in the I/P harness. Refer to Computer/Integrating Systems Component Views. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 6813 HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is internal to the energy storage control module (ESCM). The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a "heartbeat" of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All DTCs set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 6814 Data Link Connector: Testing and Inspection DATA LINK REFERENCES Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 6815 This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. This table is used to assist in correcting a communication malfunction between the control module and the scan tool. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 6816 Data Link Connector: Service and Repair DATA LINK CONNECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the bolt from the data link connector (DLC). 2. Remove the DLC from the instrument panel (I/P). INSTALLATION PROCEDURE 1. Install the DLC to the I/P. 2. Install the DLC bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations Throttle Actuator Control (TAC) Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 6820 Electronic Throttle Actuator: Diagrams Throttle Actuator Control (TAC) Module C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 6821 Throttle Actuator Control (TAC) Module C2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 6822 Electronic Throttle Actuator: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) SYSTEM DESCRIPTION The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions: - Accelerator pedal position (APP) sensing - Throttle positioning to meet driver and engine demands - Throttle position sensing - Internal diagnostics - Cruise control functions - Manage TAC electrical power consumption The TAC system components include the following: - The APP sensors - The throttle body assembly - The TAC module - The powertrain control module (PCM) Accelerator Pedal Position (APP) Sensor The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Throttle Body Assembly The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a conventional throttle body with the following exceptions: An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens. Throttle Actuator Control Module The throttle actuator control (TAC) module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the powertrain control module (PCM) through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Powertrain Control Module The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line. Modes Of Operation Normal Mode During the operation of the throttle actuator control (TAC) system, several modes or functions are considered normal. The following modes may be entered during normal operation: Minimum pedal value-At key-up the powertrain control module (PCM) updates the learned minimum pedal value. - Minimum throttle position (TP) values-At key-up the PCM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position. - Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 6823 mode, the control module commands the maximum pulse width several times to the throttle actuator motor in the closing direction. - Battery saver mode-After a predetermined time without engine RPM, the control module commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the PCM detects a condition with the TAC system, the PCM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: Acceleration limiting-The control module will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited. - Limited throttle mode-The control module will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited. - Throttle default mode-The control module will turn off the throttle actuator motor and the throttle will return to the spring loaded default position. - Forced idle mode-The control module will perform the following actions: Limit engine speed to idle by positioning throttle position, or by controlling fuel and spark if throttle is turned off. - Ignore accelerator pedal input. - Engine shutdown mode-The control module will disable fuel and de-energize the throttle actuator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 6824 Electronic Throttle Actuator: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the instrument panel harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 6825 1. Install the TAC module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls MIL ON/Misfire/Misfire DTC's Set > Page 6834 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6840 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6845 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6846 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6847 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6852 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6853 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6854 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 6859 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6869 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6874 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6875 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6876 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6881 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6882 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6883 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 6888 Powertrain Control Module (PCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 Engine Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Powertrain Control Module (PCM) C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 Powertrain Control Module (PCM) C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 Powertrain Control Module (PCM) C2 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 Powertrain Control Module (PCM) C2 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 Powertrain Control Module (PCM) C2 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6969 - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6970 Engine Control Module: Description and Operation Throttle Actuator Control (TAC) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6971 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6972 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NOS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6973 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: - Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6974 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6975 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 6979 Fuel Level Sensor: Application and ID FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 6980 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement 2 FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 6983 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 6984 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 6985 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT (4.8L, 5.3L, AND 6.0L ENGINES) REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6989 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6990 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6991 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device Information Bus: Testing and Inspection Scan Tool Does Not Communicate with Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the data link connector (DLC) allows communication with the modules for diagnostic purposes. DIAGNOSTIC AIDS The engine will not start when there is a total loss of class 2 serial data communication while the ignition is OFF. The following conditions will cause a total loss of class 2 serial data communication: A class 2 serial data circuit shorted to ground. - A class 2 serial data circuit shorted to voltage. - An internal condition within a module or connector on the class 2 serial data circuit, that causes a short to voltage or ground to the class 2 serial data circuit. TEST DESCRIPTION Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 6996 Steps 1-11 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 6997 Steps 12-19 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 6998 Steps 20-27 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 6999 - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 3. The following DTCs may be retrieved with a history status, but are not the cause of the present condition. - U1300 - U1301 - U1305 6. A state of health DTC with a history status may be present along with a U1000 or U1255 code having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 10. A poor connection at DLC terminal of the splice pack SP205 would cause this condition but will not set a DTC. 11. An open or a short in the class 2 serial data circuit between the DLC and splice pack SP205 will prevent the scan tool from communicating with any module. This condition will not set a DTC. 13. This test isolates the BCM class 2 serial data circuits. 16. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the splice pack SP207 serial data circuits. 21. This test isolates the rest of the splice pack SP205 serial data circuits. 25. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 26. The communication malfunction may have prevented diagnosis of the customer complaint. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 7000 Information Bus: Testing and Inspection Scan Tool Does Not Communicate with High Speed GMLAN Device SCAN TOOL DOES NOT COMMUNICATE WITH HIGH SPEED GMLAN DEVICE CIRCUIT DESCRIPTION Modules connected to the high speed GMLAN serial data circuits monitor for serial data communications on the high speed GMLAN network during normal vehicle operation. Operating information and commands are exchanged among the modules. The scan tool communicates with the following modules via the high speed GMLAN: Energy Storage Control Module (ESCM) - Starter/Generator Control Module (SGCM) - Electro-Hydraulic Power Steering (EHPS) Module DIAGNOSTIC AIDS IMPORTANT: The tool communication with the modules connected only to high speed GMLAN data link requires the use of the CANdi module. Due to configuration of this vehicle, they may be communication DTCs set against modules that are able to communicate with the scan tool. The following conditions may cause a total loss of high speed GMLAN data communication: A short between high speed GMLAN (+) and high speed GMLAN (-) circuits - Any of the high speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN circuits TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 7001 Steps 1-9 Step 10 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Scan Tool Does Not Communicate with Class 2 Device > Page 7002 Information Bus: Testing and Inspection Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly, the malfunction must be due to the scan tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7079 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7080 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7081 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL FUNCTION - The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION - The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Testing for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests and General Diagnostics TEST DESCRIPTION Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 7087 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 7088 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL FUNCTION - The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL ILLUMINATION - The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 7089 Step 1 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 7090 Step 14 - Step 16 The number below refers to the step number on the diagnostic table. 4. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7094 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7095 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7096 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 7103 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors (HO2S) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Oxygen Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7182 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7183 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7184 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7185 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7186 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7187 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7188 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module (BCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 Body Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7206 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7207 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7208 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7209 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7210 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Splice Pack - SP205 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Splice Pack - SP207 (Without RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Splice Pack - SP207 (With RPO Code Y91) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Body Control Module: Electrical Diagrams Door Control Module Diagrams Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Body Control System Diagrams Body Control System Schematics Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Power, Ground, and Serial Data Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Interior Lights and Interior Lights Dimming References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 Headlights and Exterior Lights References Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Controlled/Monitored Subsystem References - 1 of 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Controlled/Monitored Subsystem References - 2 of 2 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 7288 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the Body Control Module (BCM) fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the Powertrain Control Module (PCM). If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 7289 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7292 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up See: Information Bus/Testing and Inspection/Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device See: Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with Class 2 Device - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Information Bus/Testing and Inspection/Scan Tool Does Not Communicate with High Speed GMLAN Device - Power Mode Mismatch See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Retained Accessory Power (RAP) On After Time-Out - Retained Accessory Power (RAP) Inoperative See: Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7293 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7294 Steps 1-6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 7295 Body Control Module: Service and Repair BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 7296 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 7305 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 7311 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7316 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7317 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7318 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7323 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7324 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7325 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 7330 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 7340 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7345 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7346 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7347 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7352 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7353 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 7354 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 7359 Powertrain Control Module (PCM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 Engine Control Module: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 Powertrain Control Module (PCM) C1 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 Powertrain Control Module (PCM) C1 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 Powertrain Control Module (PCM) C2 (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 Powertrain Control Module (PCM) C2 (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 Powertrain Control Module (PCM) C2 (Part 3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 7440 - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 7441 Engine Control Module: Description and Operation Throttle Actuator Control (TAC) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 7442 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 7443 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NOS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 7444 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: - Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 7445 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 7446 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7451 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7452 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7453 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7454 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7455 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7484 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7485 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7486 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7487 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7488 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7489 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7492 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7499 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7500 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7501 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7502 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7503 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7504 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7505 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7506 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7507 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7510 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 7532 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 7533 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Current Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7553 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7554 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7555 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7563 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7564 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7565 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7566 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7567 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7568 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7569 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7598 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7604 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7605 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 7612 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 7613 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission Clutch Switch: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 7618 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 7619 Clutch Switch: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 7620 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 7621 Clutch Switch: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > NV 3500 - Manual Transmission > Page 7622 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7631 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7632 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7633 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7634 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7640 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7641 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7642 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7643 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7649 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 7658 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 7667 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7676 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7681 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7682 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7687 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7688 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7689 Method 1 Method 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7690 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7696 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 7705 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 7714 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7723 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7728 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7729 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7734 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7735 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7736 Method 1 Method 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 7737 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7738 Left Side Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7739 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7740 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7741 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7812 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7813 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7814 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7815 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7816 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 7817 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 7820 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 7821 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 7825 Fuel Level Sensor: Application and ID FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 7826 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement 2 FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 7829 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 7830 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Sender Assembly Replacement 2 > Page 7831 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT (4.8L, 5.3L, AND 6.0L ENGINES) REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 7835 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 7836 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 7837 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 7841 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 7842 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 7843 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7854 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7855 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7856 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7857 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7858 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7859 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7920 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7921 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7922 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7926 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7927 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7928 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 7935 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors (HO2S) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Oxygen Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7971 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7972 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7973 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7975 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7976 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7977 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7978 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7979 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7989 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7990 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7991 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7992 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7993 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7994 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7995 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7996 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7997 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7998 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7999 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8001 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8002 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8003 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8004 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8005 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8006 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8007 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8008 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8009 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8010 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8011 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8014 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8015 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8016 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8017 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8018 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8019 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 8020 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8049 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8050 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8051 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8052 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8053 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8054 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8055 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8056 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8057 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8058 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8059 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8060 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8061 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8062 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8066 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8067 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8068 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8069 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8070 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8071 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 8098 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 8099 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8102 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8105 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8108 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8109 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8110 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8111 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8112 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8113 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8170 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8171 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8172 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 8191 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 8192 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8195 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8198 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8201 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8202 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8203 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8204 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8205 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8206 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8212 Catalytic Converter: Service and Repair Catalytic Converter Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped, unclip the oxygen sensor connection from the floor reinforcement. 3. Disconnect the oxygen sensor electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8213 4. Remove the oxygen sensor clips from the frame. 5. Disconnect the connector position assurance (CPA) retainers. 6. Disconnect the oxygen sensor electrical connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8214 7. Unclip the oxygen sensors electrical connectors from the following: - Hose clip - Transmission crossmember 8. Disconnect the CPA retainers. 9. Disconnect the oxygen sensor electrical connectors (1, 2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8215 10. Remove the left exhaust manifold pipe nuts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8216 11. Remove the right exhaust manifold pipe nuts. 12. Remove the exhaust muffler nuts. 13. Remove the catalytic converter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8217 14. If necessary, remove the oxygen sensors. Installation Procedure Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8218 1. If necessary, install the oxygen sensors. 1.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 1.2. Install the oxygen sensors. Tighten Tighten the sensors to 42 Nm (31 lb ft). 2. Install the catalytic convertor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8219 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8220 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the exhaust manifold pipe nuts. Tighten Tighten the nuts to 50 Nm (39 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8221 7. Install the exhaust muffler nuts. Tighten Tighten the nuts to 40 Nm (30 lb ft). 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: - Hose clip - Transmission crossmember Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8222 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 8223 14. Connect the oxygen sensor electrical connector. 15. If equipped, clip the oxygen sensor connection to the floor reinforcement. 16. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8233 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8234 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8235 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8236 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8242 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8243 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8244 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8245 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 8249 Evaporative Emission (EVAP) Canister Purge Solenoid Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 8250 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID VALVE The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid valve opens when commanded ON by the control module. This normally closed valve is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 8251 Canister Purge Solenoid: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Remove the evaporative emission (EVAP) line from the canister purge solenoid, perform the following: 1. Push the large size white retainer portion in. 2. Push down, while pulling up slightly in order the disengage the tube. 3. Disconnect the EVAP canister purge solenoid electrical connector (1). 4. Remove the EVAP canister purge solenoid bolt (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 8252 5. Remove the EVAP canister purge solenoid (3) and insulator (1). INSTALLATION PROCEDURE 1. Install the insulator (1) onto the EVAP canister purge solenoid (3). 2. Install the EVAP canister purge solenoid (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP canister purge solenoid bolt (2). Tighten the bolt to 10.5 N.m (93 lb in). 4. Connect the EVAP canister purge solenoid electrical connector (1). 5. Install the EVAP line to the canister purge solenoid (1). 6. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8261 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8262 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8263 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8264 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8270 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8271 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8272 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8273 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8282 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8283 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8284 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8285 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8291 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8292 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8293 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8294 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8303 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8304 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8305 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8306 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8312 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8313 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8314 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 8315 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Canister Vent Valve: Locations Chassis Mounted Fuel/EVAP Controls - 10 Series Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 8320 Chassis Mounted Fuel/EVAP Controls - 20/30 Series Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 8321 Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 8322 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID VALVE The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module commands the valve ON, closing the valve during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement Canister Vent Valve: Service and Repair Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the harness clip from the canister vent solenoid (CVS) line. 3. Disconnect the CVS electrical connector. 4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister. 5. Remove the CVS clip from the frame crossmember. 6. Push in the retainer and remove the CVS from the fuel tank clip. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8325 7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister. 8. Remove the CVS clip from the frame crossmember. 9. Push in the retainer and remove the CVS from the fuel tank clip. 10. If the vehicle is equipped with a 5 ft 8 in box, disconnect the EVAP CVS electrical connector. 11. Disconnect the EVAP CVS line (3) from the canister. 12. Remove the CVS clip (2) from the frame. 13. Remove the CVS bracket bolt (1), if required otherwise push in the retainer and remove the CVS from the bracket. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8326 1. If the vehicle is equipped with a 5 ft 8 in box, install the CVS bracket bolt (1) if required, otherwise install the CVS to the bracket until the clip engages. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 12 N.m (106 lb in). 2. Connect the EVAP CVS line (3) to the canister. 3. Install the CVS clip (2) to the frame. 4. Connect the EVAP CVS electrical connector. 5. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember. 6. Install the CVS clip to the frame crossmember. 7. Connect the EVAP CVS line to the canister. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8327 8. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 6 ft box, the CVS line is routed above the frame crossmember. 9. Install the CVS clip to the frame crossmember. 10. Connect the EVAP CVS line to the canister. 11. Connect the CVS electrical connector. 12. Install the harness clip to the canister vent solenoid (CVS) line. 13. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8328 Canister Vent Valve: Service and Repair Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean all evaporative emission (EVAP) connections and surrounding areas before disconnecting the line in order to avoid possible EVAP system contamination. 1. Disconnect the EVAP canister vent solenoid (CVS) electrical connector (1). 2. Remove the EVAP CVS valve bracket bolt (1). 3. Remove the EVAP CVS line from the clips on the fuel tank. 4. Remove the CVS valve and line. 5. Remove the EVAP CVS valve line from the CVS, if necessary. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8329 1. Install the EVAP CVS valve line to the CVS, if necessary. 2. Install the CVS valve and line. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP CVS valve bracket bolt (1). Tighten the bolt to 12 N.m (106 lb in). 4. Install the EVAP CVS line to the clips on the fuel tank. 5. Connect the EVAP CVS electrical connector (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8330 Canister Vent Valve: Service and Repair Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Crew Cab) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (CREW CAB) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the canister vent solenoid (CVS) electrical connector (1). 3. Remove the CVS bracket bolt. 4. Disconnect the CVS line from the evaporative emission (EVAP) canister. 5. Remove the CVS from the vehicle. 6. If necessary, remove the CVS from the CVS bracket. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement > Page 8331 1. If necessary, install the CVS to the CVS bracket. 2. Install the CVS to the vehicle. Ensure the locator tab is inserted into the frame hole. 3. Connect the CVS line to the canister. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CVS bracket bolt. Tighten the bolt to 12 N.m (106 lb in). 5. Connect the CVS electrical connector (1). 6. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. 4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed and EVAP lines. 2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. 3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. 4. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8336 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CANISTER/FUEL TANK (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination. 1. Remove the EVAP canister. 2. Remove the EVAP canister line (1). 3. Remove the EVAP canister purge line (2). 4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel and EVAP lines. 2. Install the EVAP canister purge line (2). 3. Install the EVAP canister line (1). 4. Install the EVAP canister. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8337 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8338 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the fuel and EVAP bundle nuts. 13. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8339 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8340 5. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 6. Install the fuel line clip(s) to the bracket(s) on the transmission. 7. Install the fuel pipe bracket to the bellhousing stud. 8. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 9. Lower the vehicle. 10. Remove the cap from the fuel rail. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8341 11. Connect the fuel feed line (1) at the engine. 12. Connect the EVAP canister purge tube line (2). 13. Install the fuel fill cap. 14. Connect the negative battery cable. 15. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8342 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8343 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. 2. Install the rear fuel line bundle clip nuts. 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines from the rear tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8344 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines from the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8345 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. 4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed and EVAP lines. 2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. 3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. 4. Install the fuel tank. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CANISTER/FUEL TANK (CAB/CHASSIS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8346 REMOVAL PROCEDURE IMPORTANT: Clean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination. 1. Remove the EVAP canister. 2. Remove the EVAP canister line (1). 3. Remove the EVAP canister purge line (2). 4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel and EVAP lines. 2. Install the EVAP canister purge line (2). 3. Install the EVAP canister line (1). 4. Install the EVAP canister. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8347 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8348 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the fuel and EVAP bundle nuts. 13. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8349 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 6. Install the fuel line clip(s) to the bracket(s) on the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8350 7. Install the fuel pipe bracket to the bellhousing stud. 8. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 9. Lower the vehicle. 10. Remove the cap from the fuel rail. 11. Connect the fuel feed line (1) at the engine. 12. Connect the EVAP canister purge tube line (2). 13. Install the fuel fill cap. 14. Connect the negative battery cable. 15. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8351 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8352 INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. 2. Install the rear fuel line bundle clip nuts. 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines from the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8353 6. Connect the fuel feed and pressure balance lines from the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis (Crew Cab) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8354 9. Remove the fuel line clips from the brackets on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8355 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8356 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clips to the brackets on the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8357 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - ENGINE REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Cab/Chassis > Page 8358 1. Remove the engine sight shield. 2. Disconnect the EVAP tube from the EVAP canister purge solenoid (1). 1. Push the large side white retainer portion in. 2. Push down, while pulling up slightly in order to disengage the tube. 3. Disconnect the EVAP tube from the chassis EVAP pipe (2). 1. Push the large side white retainer portion in. 2. Push down, while pulling up slightly in order to disengage the tube. 4. Remove the EVAP tube. 5. Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe. 2. Install the EVAP tube. 3. Connect the EVAP tube to the EVAP chassis pipe (2). 4. Connect the EVAP tube to the EVAP purge solenoid (1). 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation ON-BOARD REFUELING VAPOR RECOVERY SYSTEM (ORVR) The On-Board Refueling Vapor Recovery System (ORVR) is an on-board vehicle system designed to recover fuel vapors during the vehicle refueling operation. The flow of liquid fuel down the fuel filler pipe provides a liquid seal which prevents vapor from leaving the fuel filler pipe. An evaporative emission (EVAP) pipe transports the fuel vapor to the EVAP canister for use by the engine. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Remove the engine sight shield. 2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and valve rocker arm cover. 3. Remove the vent hose from the throttle body and the valve rocker arm cover. 4. Replace the hose as necessary. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 8369 1. Install the hose as necessary. 2. Install the vent hose to the throttle body and the valve rocker arm cover. 3. Install the PCV hose to the intake manifold and valve rocker arm cover. 4. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 8376 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 8377 Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 8378 Step 6 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 8383 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8390 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8391 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8392 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8393 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8394 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 8407 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 8413 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 8414 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 8415 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8458 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8459 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 8492 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 8493 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8498 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8499 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8500 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8501 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8502 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8503 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 8504 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 8505 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane rating of 87 or higher. If the octane rating is less than 87, you may notice an audible knocking noise when you drive, commonly referred to as spark knock. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. If you are using gasoline rated at 87 octane or higher and you hear heavy knocking, your engine needs service. GASOLINE SPECIFICATIONS It is recommended that gasoline meet specifications which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org/fuel_charter.htm. Gasoline meeting these specifications could provide improved driveability and emission control system performance compared to other gasoline. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards, it is designed to operate on fuels that meet California specifications. See the underhood emission control label. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on and your vehicle may fail a smog-check test. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. ADDITIVES To provide cleaner air, all gasolines in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. In most cases, you should not have to add anything to your fuel. However, some gasolines contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasolines that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Also, your GM dealer has additives that will help correct and prevent most deposit-related problems. Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in your area to contribute to clean air. General Motors recommends that you use these gasolines, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Without Special Tool Fuel: Testing and Inspection Without Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL AND E85) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack or power, stalling, or no start. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Refer to Fuel System Cleaning. See: Service and Repair Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Without Special Tool > Page 8508 Fuel: Testing and Inspection With Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent in non-blended gasoline, or greater than 85 percent with E85 blended gasoline for flexible fuel applications, can cause driveability conditions and may contribute to fuel system deterioration. Excessive ethanol concentrations can result in driveability conditions such as hesitation, lack of power, stalling, or a no start, and may contribute to fuel system corrosion, deterioration of fuel system components, and a restricted fuel filter. TEST PROCEDURE 1. Test the fuel composition using J 44175 Fuel Composition Tester and J 44175-3 Instruction Manual. 2. If water appears in the fuel sample, perform the following steps: 1. Clean the fuel system. Refer to Fuel System Cleaning. See: Service and Repair 2. Replace the fuel filter if the vehicle is equipped with a serviceable fuel filter. Fuel Composition Test Examples 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 4. If the non-blended gasoline fuel sample contains more than 15 percent ethanol, or if the E85 blended gasoline fuel sample contains more than 85 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 5. Test the fuel composition. 6. If additional testing indicates that the ethanol percentage is still more above 15 percent for a non-blended gasoline sample, drain and replace the vehicle's fuel. Refer to Fuel System Cleaning. If additional testing indicates that the E85 blended gasoline sample is still above 85 percent, continue adding fresh, regular gasoline until the ethanol content is 85 percent or less. See: Service and Repair Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation FUEL FILLER CAP The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear clicks. This indicates that the cap is correctly torqued and fully seated. A built-in device indicates that the fuel filler cap is fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief Procedure > Page 8517 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 8526 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 8527 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 8528 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 8529 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 8535 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 8536 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 8537 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 8538 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-04-051B > Jan > 06 > Fuel System Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8548 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8549 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8550 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8556 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8557 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8558 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 Fuel Injector: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8581 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8582 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8583 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8584 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8585 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8586 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8604 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8605 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8606 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8607 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8608 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8609 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8610 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8611 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8612 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8613 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 Fuel Injector: Connector Views Fuel Injector 1 Fuel Injector 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 Fuel Injector 3 Fuel Injector 4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Fuel Injector 5 Fuel Injector 6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 Fuel Injector 7 Fuel Injector 8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel System Fuel Injector: Description and Operation Fuel System FUEL INJECTORS The fuel injector assembly is a solenoid device controlled by the powertrain control module (PCM) that meters pressurized fuel to a single engine cylinder. The PCM energizes the injector solenoid to open a normally closed ball valve. This allows the fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel System > Page 8637 Fuel Injector: Description and Operation Fuel System (Cab Chassis) FUEL INJECTORS The Multec 2 fuel injector assembly is a solenoid device, controlled by the powertrain control module (PCM), that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has 2 machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool Fuel Injector: Testing and Inspection Fuel Injector Balance Test With Special Tool FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL DESCRIPTION Fuel Injector Balance Test With Special Tool Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool > Page 8640 Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool > Page 8641 Step 6 - Step 8 The number below refers to the step number on the diagnostic table. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Refer to the illustration. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool > Page 8642 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 FUEL INJECTOR BALANCE TEST WITH TECH 2 DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump. The scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare the flow through each injector. TEST DESCRIPTION Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool > Page 8643 Step 1 - Step 4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool > Page 8644 Step 5 - Step 7 The number below refers to the step number on the diagnostic table. 5. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test With Special Tool > Page 8645 Fuel Injector: Testing and Inspection Fuel Injector Coil Test FUEL INJECTOR COIL TEST CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - The use of Dielectric compound GM P/N 12377900 (Canadian P/N 10953529) in the fuel injector electrical connector may eliminate a corrosion condition. - Monitoring the misfire current counters, or misfire graph, may help isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customers concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. - If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Injector Balance Test With Special Tool TEST Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Replacement Fuel Injector: Service and Repair Fuel Injector Replacement FUEL INJECTOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel rail. 2. Remove and discard the fuel injector retainer clip (19). 3. Remove the fuel injector (17). 4. Remove and discard the fuel injector retainer clip (1). 5. Remove and discard the fuel injector O-ring seals (2, 4). INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, you must order the correct injector for the application being serviced. The fuel injector (1) is stamped with a identification part number (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Replacement > Page 8648 1. Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil. 2. Install the NEW injector O-ring seals onto the fuel injector. 3. Install a NEW retainer clip (1) onto the fuel injector. 4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket. 5. Install the fuel rail. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Replacement > Page 8649 Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure FUEL INJECTOR CLEANING PROCEDURE TOOLS REQUIRED - J 37287 Fuel Line Shut-Off Adapters - J 35800-A Fuel Injector Cleaner - J 42873-1 3/8 Fuel Line Shut-Off Valve - J 42873-2 5/16 Return Pipe Shut-Off Valve - J 42964-1 3/8 Fuel Pipe Shut-Off Valve - J 42964-2 5/16 Fuel Pipe Shut-Off Valve NOTE: - GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. - Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. - Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure. IMPORTANT: - Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced. - During this procedure you will need a total of 960 ml (32.4 oz) of cleaning solution. That is 2 tanks of solution for the J 35800-A. Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 oz) of solution to ensure complete injector cleaning. 1. Obtain J 35800-A (2). 2. For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 35800-A. IMPORTANT: Make sure the valve at the bottom of the canister (3) is closed. 3. For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 35800-A. 4. If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline. 5. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 6. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 7. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel system. 8. Connect the J 35800-A to the vehicle fuel rail. 9. Pressurize the J 35800-A to 510 kPa (75 psi). 10. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes. 11. Disconnect J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Replacement > Page 8650 13. Remove J 37287 or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector. 16. Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop. 17. Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. 18. Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 5000 km (3,000 mi). GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure. 19. Road test the vehicle to verify that the customer concern has been corrected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings located inside the female connector provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(s) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(s) Service (Metal Collar) QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR) TOOLS REQUIRED - J 41769 Fuel Line Quick Disconnect Tool - J 43178 Fuel Line Disconnect Tool REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the fuel feed line to engine quick-connect fitting. 3. If equipped with the 5.3L (L59) engine, remove the retainers from the fuel feed and return line to engine quick-connect fittings. 4. Using compressed air, blow any dirt or debris from around the fitting. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(s) Service (Metal Collar) > Page 8656 5. Using the correct tool from J 41769, insert the tool into the female connector, then push inward in order to release the quick connect locking tabs. 6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect locking tabs. 7. Pull the fuel line connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 8. Use a clean shop towel in order to wipe off the male connection end. 9. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male connection end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the fittings together in order to snap the retaining tabs into place. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(s) Service (Metal Collar) > Page 8657 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. 4. If equipped with the 5.3L (L59) engine, install the retainers to the fuel feed and return line to engine quick-connect fittings. 5. Install the retainer to the fuel feed line quick-connect fitting. 6. Install the fuel fill cap. 7. Connect the negative battery cable. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(s) Service (Metal Collar) > Page 8658 Fuel Line Coupler: Service and Repair Quick Connect Fitting(s) Service (Plastic Collar) QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) REMOVAL PROCEDURE IMPORTANT: There are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Using compressed air, blow any dirt or debris from around the quick connect fitting. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY) 4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(s) Service (Metal Collar) > Page 8659 5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. 6. Pull the quick connect fitting connection apart. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male connection end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(s) Service (Metal Collar) > Page 8660 3. Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel System Fuel Pressure Regulator: Description and Operation Fuel System FUEL PRESSURE REGULATOR The fuel pressure regulator is contained in the fuel sender assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel System > Page 8665 Fuel Pressure Regulator: Description and Operation Fuel System (Cab Chassis) FUEL PRESSURE REGULATOR ASSEMBLY The fuel pressure regulator is a vacuum operated diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator compensates for changes in intake manifold vacuum by changing the fuel pressure. In this way, the fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 8672 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 8673 Step 1 - Step 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 8674 Step 6 - Step 13 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Primary Fuel Pump Relay: Locations Primary Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Primary > Page 8679 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Primary > Page 8680 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Primary > Page 8681 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Primary > Page 8682 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Primary > Page 8683 Fuel Pump Relay - Secondary (Except RPO Code NQZ) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 Fuel Pump Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8706 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8707 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8708 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8709 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8710 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8711 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8712 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8713 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8714 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8715 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8719 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8720 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8721 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8726 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8727 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8736 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8737 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8738 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8739 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8740 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8749 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System Fuel Pump Pickup Filter: Description and Operation Fuel System FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System > Page 8761 Fuel Pump Pickup Filter: Description and Operation Fuel System (Cab Chassis) FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: - Positions the injectors (3) in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel dampener (2) into the fuel metering system Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8765 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: An 8-digit identification number (1) is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the wire harness bracket nut (2). 3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1). 4. Disconnect the generator electrical connector (3). 5. Disconnect the following electrical connectors: - Manifold absolute pressure (MAP) sensor (1) - Knock sensor (2) 6. Remove the knock sensor harness connector from the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8766 7. Disconnect the electronic throttle control (ETC) electrical connector (2), preform the following: 1. Disengage the gray retainer. 2. Push down the black clip. 3. Disconnect the connector. 8. Remove the connector position assurance (CPA) retainer (5). 9. Disconnect the following electrical connectors from the right side of the engine: - Main coil (4) - Fuel injectors (3) 10. Remove the harness clips from the fuel rail (1). 11. Remove the CPA retainer from the left side of the engine. 12. Disconnect the following electrical connectors from the left side of the engine: - Main coil (2) - Fuel injectors 13. Remove the harness clips from the fuel rail (1). 14. Reposition the engine wire harness aside. 15. Perform the following steps in order to disconnect the fuel injector electrical connectors. 0. Mark the connectors to their corresponding injectors to ensure correct reassembly. 1. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. 2. Push the tab (1) on the connector in. 3. Disconnect the fuel injector electrical connector. 4. Repeat the steps for each injector electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8767 16. Remove the positive crankcase ventilation (PCV) hose. 17. Disconnect the fuel feed pipe (1) from the fuel rail. 18. Remove the fuel rail bolts. 19. Remove the fuel rail. NOTE: - Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8768 - Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. IMPORTANT: Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. 20. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary. 21. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Lubricate NEW fuel injector lower O-ring seals (4) with clean engine oil. 2. Install the NEW O-ring seals (4) onto each injector, if necessary. 3. Install the fuel rail. 4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the fuel rail bolts. 5. Install the fuel rail bolts. NOTE: Refer to the Fastener Notice in Service Precautions. Tighten the bolts to 10 N.m (89 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8769 6. Connect the fuel feed pipe (1) to the fuel rail. 7. Install the PCV hose. 8. Perform the following steps in order to connect the fuel injector electrical connectors. 1. Install the connectors to their corresponding injectors to ensure correct reassembly. 2. Connect the fuel injector electrical connector. 3. Push the CPA retainer (2) on the connector in 1 click. 4. Repeat the steps for each injector electrical connector. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8770 9. Position the engine wire harness. 10. Connect the following electrical connectors to the left side of the engine: - Main coil (2) - Fuel injectors 11. Install the harness clips to the fuel rail (1). 12. Install the CPA retainer. 13. Connect the following electrical connectors to the right side of the engine: - Main coil (4) - Fuel injectors (3) 14. Install the CPA retainer (5). 15. Install the harness clips to the fuel rail (1). 16. Connect the ETC electrical connector (2), preform the following: 0. Connect the connector. 1. Engage the gray retainer. 17. Connect the following electrical connectors: - MAP sensor (1) - Knock sensor (2) 18. Install the knock sensor harness connector to the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 8771 19. Connect the EVAP purge solenoid electrical connector (1). 20. Connect the generator electrical connector (3). 21. Install the wire harness bracket nut (2). Tighten the nut to 5 N.m (44 lb in). 22. Tighten the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 0. Turn the ignition ON, with the engine OFF, for 2 seconds. 1. Turn the ignition OFF for 10 seconds. 2. Turn the ignition ON, with the engine OFF. 3. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Fuel System Fuel Return Line: Description and Operation Fuel System NYLON FUEL PIPES CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: 9.5 mm (3/8 in) ID for the fuel supply, 7.6 mm (5/16 in) ID for the fuel return, and 12.7 mm (1/2 in) ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protects the sections of the pipes that are exposed to chafing, to high temperatures, or to vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. FUEL PIPE O-RINGS O-rings seal the threaded connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Fuel System > Page 8776 Fuel Return Line: Description and Operation Fuel System (Cab Chassis) NYLON FUEL PIPES Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. FUEL PIPE O-RINGS O-rings seal the connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tanks. The fuel pipes consist of 2 sections: - The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. The chassis fuel pipes are constructed of steel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) Fuel Return Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8779 Fuel Return Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Crew Cab)) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8780 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8781 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8782 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8783 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8784 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8785 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8786 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8787 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8788 14. Remove the fuel and EVAP bundle nuts. 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8789 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8790 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 11. Lower the vehicle. 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8791 Fuel Return Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Assembly Replacement (Crew Cab)) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8792 IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Replacement - Chassis FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8793 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8794 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8795 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8796 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8797 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8798 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8799 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8800 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. 14. Remove the fuel and EVAP bundle nuts. 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8801 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8802 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8803 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Rear) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - REAR) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8804 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fuel line bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8805 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines to the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines to the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8806 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure . 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8807 9. Remove the fuel line clip from the bracket on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). 18. Remove the torsion bar bracket, if equipped with 4WD. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8808 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8809 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clip to the bracket on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8810 Tighten the nut to 10 N.m (89 lb in) 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel System Fuel Supply Line: Description and Operation Fuel System NYLON FUEL PIPES CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: 9.5 mm (3/8 in) ID for the fuel supply, 7.6 mm (5/16 in) ID for the fuel return, and 12.7 mm (1/2 in) ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protects the sections of the pipes that are exposed to chafing, to high temperatures, or to vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. FUEL PIPE O-RINGS O-rings seal the threaded connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel System > Page 8815 Fuel Supply Line: Description and Operation Fuel System (Cab Chassis) NYLON FUEL PIPES Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. FUEL PIPE O-RINGS O-rings seal the connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tanks. The fuel pipes consist of 2 sections: - The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. The chassis fuel pipes are constructed of steel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8818 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Crew Cab)) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8819 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8820 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8821 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8822 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8823 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8824 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8825 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8826 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8827 14. Remove the fuel and EVAP bundle nuts. 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8828 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8829 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 11. Lower the vehicle. 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8830 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Assembly Replacement (Crew Cab)) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8831 IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Replacement - Chassis FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8832 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8833 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8834 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8835 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8836 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8837 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8838 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8839 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. 14. Remove the fuel and EVAP bundle nuts. 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8840 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8841 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 11. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8842 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Rear) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - REAR) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8843 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fuel line bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8844 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines to the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines to the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8845 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure . 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8846 9. Remove the fuel line clip from the bracket on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). 18. Remove the torsion bar bracket, if equipped with 4WD. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8847 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8848 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clip to the bracket on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Cab/Chassis) > Page 8849 Tighten the nut to 10 N.m (89 lb in) 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Fuel System Fuel Filler Hose: Description and Operation Fuel System FUEL FILL PIPE The fuel fill pipe has a built-in restrictor in order to prevent refueling with leaded fuel. When refueling dual tank applications, fuel is dispensed to both the front and rear fuel tanks at the same time. Once the fill vent is obstructed, fuel backs up the fill pipe and trips the dispensing nozzle. The front fuel tank vent runs into the rear tank to the top of the filler pipe assembly, which in turn vents to atmosphere. The fuel tank vent valves are connected and route to the canister to collect hydrocarbon emissions during operation of the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Fuel System > Page 8855 Fuel Filler Hose: Description and Operation Fuel System (Cab Chassis) FUEL FILL PIPE The fuel fill pipe has a built-in restrictor in order to prevent refueling with leaded fuel. Once the fill vent is obstructed, fuel backs up the fill pipe and trips the dispensing nozzle. The front fuel tank vent runs into the rear tank to the top of the filler pipe assembly, which in turn vents to atmosphere. The fuel tank vent valves are connected and route to the canister to collect hydrocarbon emissions during operation of the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement Fuel Filler Hose: Service and Repair Filler Tube Replacement FILLER TUBE REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(r) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt (1). 6. Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8858 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 11. Disconnect the recirculation line from the sending unit. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8859 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the recirculation line to the sending unit. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 N.m (22 lb in). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. 7. Position the fuel tank fill pipe ground wire and chassis harness ground wire (2). 8. Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (1). Tighten the bolt to 9 N.m (80 lb in). 10. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8860 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 N.m (20 lb in). 13. Install the fuel tank filler housing to body TORX(r) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8861 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Crew Cab) FILLER TUBE REPLACEMENT (CREW CAB) REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(r) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt. 6. Remove the fuel tank fill pipe ground wire from the frame. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8862 7. Loosen the fuel tank fill pipe clamp at the fuel tank. 8. Disconnect the recirculation line quick connect fitting at the tank. 9. Remove the fuel tank fill pipe. 10. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the recirculation line quick connect fitting at the tank. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank fill pipe clamp at the fuel tank. Tighten the clamp to 2.5 N.m (22 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8863 5. Position the fuel tank fill pipe ground wire to the frame. Ensure the anti-rotation tab is positioned correctly. 6. Install the fuel tank fill pipe ground wire bolt. Tighten the bolt to 9 N.m (80 lb in). 7. Lower the vehicle. 8. Install the fuel tank filler housing. 9. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 N.m (20 lb in). 10. Install the fuel tank filler housing to body TORX(r) screws (1) and retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8864 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Cab/Chassis - Front) FILLER TUBE REPLACEMENT (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. 3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination. 4. Loosen the fuel fill pipe clamp (2) at the tank. 5. Loosen the vent pipe clamp (1) at the tank. 6. Remove the fuel fill pipe and vent pipe from the tank. 7. Cap the fuel and vent openings in the tank in order to prevent possible system contamination. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8865 1. Remove the caps from the fuel and vent openings in the tank. 2. Install the fuel fill pipe and vent pipe to the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the vent pipe clamp (1) at the tank. 4. Tighten the fuel fill pipe clamp (2) at the tank. Tighten the clamps to 2.5 N.m (22 lb in). 5. Remove the caps from the fuel feed and EVAP pipes. 6. If equipped with a rear auxiliary tank, connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 8866 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Cab/Chassis - Rear) FILLER TUBE REPLACEMENT (CAB/CHASSIS - REAR) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Loosen the fuel fill pipe hose clamp (2) at the tank. 3. Loosen the fuel vent pipe hose clamp (1) at the tank. 4. Remove the fuel fill and vent hoses from the tank. INSTALLATION PROCEDURE 1. Install the fuel fill and vent hoses to the tank. 2. Tighten the fuel vent pipe hose clamp (1) at the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten the clamps to 2.5 N.m (22 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Fuel System - Fuel Filler Neck Flapper Door Elimination Fuel Filler Neck: Technical Service Bulletins Fuel System - Fuel Filler Neck Flapper Door Elimination Bulletin No.: 06-06-04-006 Date: January 30, 2006 INFORMATION Subject: Elimination of Fuel Filler Tube Flapper Door Models: 2006 GM Passenger Cars and Light Duty Trucks 2006 HUMMER H2, H3 2006 Saab 9-7X Attention: The flapper door located in the fuel filler neck has been eliminated on the current Buick LaCrosse (Buick Allure, Canada Only) in production. This change will be progressively rolled into the other GM products listed above. Do Not attempt to change the fuel filler tube because the flapper is not present. New Metal Fuel Filler Tubes Without a Flapper Door A revised style of fuel filler tube has changed materials from plastic to metal construction. On plastic fuel filler necks, the metal flapper was included as a safe discharge point for static electricity. With the metal style of fuel filler tube, the entire neck serves as the static discharge point making the flapper redundant. Important: Do Not attempt to change the fuel filler tube because the flapper is not present. Replacement fuel filler tubes will not be equipped with the flapper. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System Fuel Gauge Sender: Description and Operation Fuel System FUEL SENDER ASSEMBLY The front fuel sender on dual tank applications consists of the following major components: - The fuel level sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter The rear fuel sender on dual tank applications consists of the following major components: - The fuel level sensor (4) - The FTP sensor (1) - The rear fuel pump (2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System > Page 8875 The fuel sender assembly on single tank applications consists of the following major components: - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System > Page 8876 Fuel Gauge Sender: Description and Operation Fuel System (Cab Chassis) FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: The fuel sender assembly (2) - The fuel strainer (3) - The fuel pump (4) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 8877 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 8878 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 8879 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Tank Unit: Diagrams Fuel Pump/Sender Assembly - Primary Fuel Pump/Sender Assembly - Secondary Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 8883 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. - Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces.Turn the fuel sender lock ring in a counterclockwise direction. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 8884 7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. IMPORTANT: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. - Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. - Check the lock ring for flatness. 8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install the sending unit. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. - Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Connect the EVAP line to the sending unit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 8885 4. Connect the fuel line to the sending unit. 5. Install the fuel tank. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary Fuel Pump Relay: Locations Primary Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 8891 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 8892 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 8893 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 8894 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Primary > Page 8895 Fuel Pump Relay - Secondary (Except RPO Code NQZ) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8898 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8899 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8900 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8901 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8902 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Fuel Pump Relay: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8914 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8917 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8918 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8919 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8922 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8923 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8924 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8925 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8926 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8927 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8928 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8929 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8930 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8933 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8934 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8935 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8936 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8937 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8938 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8939 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8940 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8941 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8944 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8945 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8946 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8947 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8948 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8949 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8950 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8951 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8952 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8953 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8954 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8955 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8956 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8957 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8958 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8959 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8960 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8961 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8962 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8963 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8964 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8965 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8966 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8967 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8968 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8973 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8974 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8975 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL WITH POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8976 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. Install the accelerator pedal bolts. NOTE: Refer to Fastener Notice. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8977 - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8983 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8984 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8985 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8986 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8987 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8988 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8989 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8990 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8991 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8992 Air Flow Meter/Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8993 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8994 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8995 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8996 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8997 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8998 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8999 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9000 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9001 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9002 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9003 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9004 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9005 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9006 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9007 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9008 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9009 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9010 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9011 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9012 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9013 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9014 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9015 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9016 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9017 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9018 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9019 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9020 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9021 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9022 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9023 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9024 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9025 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9026 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9027 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9028 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9029 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9030 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9031 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9032 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9033 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9034 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9035 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9036 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9037 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9038 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9039 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9040 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9041 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9042 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9043 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9044 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9045 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9046 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9047 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9048 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9049 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9050 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9051 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9052 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9053 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 9054 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 9055 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9060 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9061 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9062 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9063 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9064 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9065 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9066 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9067 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9068 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9069 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9070 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9071 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9072 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9073 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9074 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9075 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9076 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9077 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9078 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9079 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9080 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9081 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9082 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9083 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9084 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9085 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9086 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9087 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9088 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9089 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9090 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9091 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9092 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9093 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9094 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9095 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9096 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9097 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9098 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9099 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9100 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9101 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9102 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9103 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9104 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9105 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9106 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9107 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9108 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9109 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9110 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9111 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9112 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9113 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9114 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9115 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9126 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9127 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9128 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9129 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams Throttle Body Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams > Page 9133 Throttle Body: Description and Operation THROTTLE BODY ASSEMBLY The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a conventional throttle body with the following exceptions: - An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. IMPORTANT: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. - An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required. 1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air cleaner outlet duct. 3. Remove the engine sight shield. 4. Disconnect the throttle actuator motor electrical connector (2). 5. Reposition the coolant air bleed hose clamp at the throttle body. 6. Remove the coolant air bleed hose from the throttle body. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 9136 7. Remove the throttle body nuts. 8. Remove the throttle body. 9. Remove and discard the throttle body gasket. INSTALLATION PROCEDURE 1. Install the NEW throttle body gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 9137 2. Install the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the throttle body nuts. Tighten the nuts to 10 N.m (89 lb in). 4. Install the coolant air bleed hose to the throttle body. 5. Position the coolant air bleed hose clamp at the throttle body. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 9138 6. Connect the throttle actuator motor electrical connector (2). IMPORTANT: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged. 7. Install the engine sight shield. 8. Install the air cleaner outlet duct. 9. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 12. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 13. Start the engine. 14. Inspect for coolant leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 9139 Throttle Body: Service and Repair Throttle Body Cleaning Procedure THROTTLE BODY CLEANING PROCEDURE 1. Remove the air cleaner intake duct. CAUTION: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. NOTE: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air cleaner intake duct. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9144 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9145 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9146 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9147 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9148 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9149 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9150 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9151 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9152 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9153 Throttle Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9154 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9155 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9156 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9157 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9158 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9159 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9160 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9167 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9168 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9169 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9170 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9171 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9172 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9173 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9174 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9175 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9176 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9177 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9178 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9179 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9180 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9181 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9182 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9183 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9184 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9185 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9186 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9187 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9188 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9189 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9190 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9191 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9192 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9193 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9194 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9195 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9196 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9197 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9198 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9199 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9200 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9201 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9202 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9203 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9205 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9206 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9211 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9212 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9213 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9219 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9220 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9221 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9222 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9223 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9224 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9225 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9226 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9227 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9228 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9229 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9230 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9231 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9232 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9233 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9234 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9235 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9236 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9237 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9238 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9239 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9240 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9241 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9242 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9243 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9244 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9245 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9246 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9247 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9248 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9249 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9250 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9251 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9252 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9253 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9254 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9255 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9256 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9257 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9258 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9259 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9260 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9261 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9263 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9264 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9265 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9266 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9267 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9268 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9269 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 9290 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 9291 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9296 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9314 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9315 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9316 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9317 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9318 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9319 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9320 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9321 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9322 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9323 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9324 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9325 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9326 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9327 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9328 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9329 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9330 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9331 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9332 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9333 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9334 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9335 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9336 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9337 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9338 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9339 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9340 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9341 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9342 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9343 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9366 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 9367 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 9370 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 9371 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1000 Ohms per ft Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 9375 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 9376 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(r) spark plug wires MUST be used only with the Melco(r) coils and bracket, like wise the Delphi(r) spark plug wires MUST be used only with Delphi(r) coils and bracket. The components are NOT interchangeable. 4. The Melco(r) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(r) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(r) (1) ignition coil is a square design. 7. The Delphi(r) (2) ignition coil is a round design. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 9377 8. The Melco(r) ignition coil bracket (1) is a square design. 9. The Delphi(r) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil: Diagrams Ignition Coil 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9381 Ignition Coil 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9382 Ignition Coil 3 Ignition Coil 4 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9383 Ignition Coil 5 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9384 Ignition Coil 6 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9385 Ignition Coil 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9386 Ignition Coil 8 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9387 Ignition Coil: Description and Operation IGNITION COILS Each ignition coil has an ignition 1 feed and a ground. The PCM supplies a low reference and an ignition control (IC) circuit. Each ignition coil contains a solid state driver module. The PCM will command the IC circuit ON, this allows the current to flow through the primary coil windings for the appropriate time or dwell. When the PCM commands the IC circuit OFF, this will interrupt current flow through the primary coil windings. The magnetic field created by the primary coil windings will collapse across the secondary coil windings, which induces a high voltage across the spark plug electrodes. The coils are current limited to prevent overloading if the IC current is held high too long. The spark plugs are connected to their respective coils by a short secondary wire. The spark plugs are tipped with iridium for long life and efficiency. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9388 Ignition Coil: Service and Repair IGNITION COIL(S) REPLACEMENT REMOVAL PROCEDURE 1. If equipped with regular production option (RPO) HP2, disconnect the energy storage box (ESB). 2. Remove the spark plug wire from the ignition coil. 3. Disconnect the ignition coil electrical connector. 4. If equipped with regular production option (RPO) HP2, remove the auxiliary heater water pump bracket bolts. 5. Remove the auxiliary heater water pump from the studs, and reposition out of the way. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9389 6. If equipped with RPO HP2, remove the starter/generator control module (SGCM) cover bolts, and cover. 7. Remove the 3-phase cable nuts to the SGCM. 8. Remove the 3-phase cable from the SGCM. 9. If equipped with RPO HP2, remove the 3-phase cable bracket nuts (2). 10. Remove the 3-phase cable bracket (1) from the studs, and reposition the cable and bracket out of the way. 11. Remove the ignition coil bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9390 12. Remove the ignition coil. INSTALLATION PROCEDURE 1. Install the ignition coil. 2. Install the ignition coil bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 8 N.m (71 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9391 3. If equipped with RPO HP2, position the cable (w/bracket) and install the 3-phase cable bracket to the studs. 4. Install the 3-phase cable bracket nuts (2). Tighten the nuts to 15 N.m (11 lb ft). 5. If equipped with RPO HP2, install the 3-phase cable to the SGCM. 6. Install the 3-phase cable nuts to the SGCM. Tighten the nuts to 9 N.m (80 lb in). 7. Install the SGCM cover and bolts. Tighten the bolts to 9 N.m (80 lb in). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 9392 8. If equipped with RPO HP2, position the auxiliary heater water pump and install it onto the studs. 9. Install the auxiliary heater water pump bracket bolts. Tighten the bolts to 15 N.m (11 lb ft). 10. Connect the ignition coil electrical connector. 11. Install the spark plug wire to the ignition coil. 12. If equipped with RPO HP2, connect the ESB. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9396 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9397 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9398 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9399 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9400 Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test (Non-HP2) Battery Inspection/Test (HP2) in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9401 Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9402 Step 8 - Step 17 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9403 Step 18 - Step 26 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 9404 Step 27 - Step 31 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9410 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9411 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9419 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9420 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9421 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9422 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9423 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9424 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9428 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9429 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9430 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9431 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9435 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9436 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9437 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9438 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9439 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9440 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9441 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9442 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9443 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9444 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9445 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9446 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9447 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9448 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9449 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9450 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9451 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9452 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9453 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9454 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9455 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9456 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9457 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9458 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9459 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9460 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9461 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9462 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9463 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9464 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9465 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9466 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9467 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9468 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9469 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9470 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9471 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9472 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9473 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9474 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9475 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9476 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9477 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9478 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9479 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9480 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 9481 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 9482 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 9483 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9488 Application Table (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9489 Application Table (Part 2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9490 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9491 Location View Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9492 Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test (Non-HP2) Battery Inspection/Test (HP2) in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9493 Step 1 - Step 7 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9494 Step 8 - Step 17 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9495 Step 18 - Step 26 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 9496 Step 27 - Step 31 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9502 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9503 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9504 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9505 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9506 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9507 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9508 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9509 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9510 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9511 Camshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9512 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9513 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9514 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9515 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9516 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9517 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9518 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9519 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9520 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9524 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9525 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9526 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9527 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9528 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9529 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9530 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9534 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9535 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9536 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9537 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9538 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9541 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9542 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9543 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9544 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9545 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9546 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9547 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9548 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9549 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9568 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9569 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9570 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9571 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9572 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 9573 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 9574 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9583 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9584 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9585 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9586 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9587 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9588 Crankshaft Position Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9589 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9590 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9591 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9592 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9593 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9594 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9595 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9596 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9597 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9598 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9599 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9600 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9601 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9602 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9603 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9604 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9605 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9606 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9607 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9608 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9609 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9610 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9611 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9612 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9613 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9614 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9615 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9616 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9617 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9618 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9619 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9620 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9621 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9622 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9623 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9624 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9625 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9626 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9627 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9628 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9629 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9630 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9631 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9632 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9633 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9634 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9635 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9636 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9637 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9638 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 9650 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 9653 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 9654 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING USE INSTRUCTION SHEET SUPPLIED For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 9661 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 3. Lower the hush and knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Console. 4. Remove the steering column trim covers. 5. With the key installed, turn the key to the RUN position. 6. Install an allen wrench into the hole on top of the lock cylinder housing. Push down on the allen wrench to release the tab on the lock cylinder inside the lock cylinder housing. 7. Slide the lock cylinder out of the lock cylinder housing. Installation Procedure 1. Install the key into the lock cylinder. 2. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 9662 Important: The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN. 3. Align the lock cylinder and install into the lock cylinder housing. 4. Install the steering column trim covers. 5. Install the hush and knee bolster. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 7. Connect the negative battery cable. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key and Lock Cylinder Coding > Page 9663 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the ignition switch. 3. Remove the turn signal cancel cam. 4. Remove the park lock cable from the lock cylinder housing. 5. Remove 3 TORX(r) screws. 6. Remove the lock cylinder housing from the steering column. Installation Procedure 1. Install 3 TORX screws into the lock cylinder housing. ^ Tighten the TORX screws to 7 Nm (62 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the turn signal cancel cam. 3. Install the park lock cable into the lock cylinder housing. 4. Install the ignition switch. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9672 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9673 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9674 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9675 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9676 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9678 Knock Sensor: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9679 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9680 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9681 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9685 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9686 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9687 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9688 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9689 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9690 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9691 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9692 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9693 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9694 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9695 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9696 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9697 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9698 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9699 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9700 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9701 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9702 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9703 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9704 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9705 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9706 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9707 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9711 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9712 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9713 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9714 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9715 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9716 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9717 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9718 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9721 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9722 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9723 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9724 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9725 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9726 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9727 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9728 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9729 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9730 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9731 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9732 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9733 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9734 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9735 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 9740 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 9741 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 9742 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................................... 1.52 mm (0.060 in.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 9747 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ................................................... 15 Nm (11.0 lb. ft.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 9748 Spark Plug: Application and ID SPARK PLUG TYPE AC Delco P/N ...................................................................................................................................... .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 9749 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). An excessively wide electrode gap can prevent correct spark plug Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 9750 operation. - Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 9751 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 9752 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9760 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9761 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9762 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9763 Clutch Control Solenoid Valve: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9764 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9765 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9766 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9767 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9772 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 9775 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Control Solenoid 2 (PCS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 9776 Pressure Switch Manifold (PSM) Pressure Switch Manifold (PSM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 9777 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 9778 Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 9779 Pressure Regulating Solenoid: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid Valve, Wiring Harness Side Pressure Control Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9782 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9783 Pressure Regulating Solenoid: Service and Repair 4L80-E/4L85-E - Automatic Transmission Pressure Regulator Replacement ^ Tools Required J 36850 Transjel(r) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the transmission filter. 3. Remove the reverse boost valve bushing retainer ring (2). Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9784 2. Pre-assemble the following parts: ^The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 9788 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State And Gear Ratio 4L60-E/4L70-E Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9793 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9796 Shift Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9799 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9800 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9801 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9802 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9803 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9804 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9805 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9806 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9807 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9808 Shift Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9809 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9810 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9811 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9812 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9813 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9814 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9815 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9816 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9817 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9818 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9819 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9820 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9821 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9822 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9823 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9824 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9825 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9826 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9827 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9828 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9829 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9830 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9831 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9832 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9833 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9834 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9835 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9836 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9837 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9838 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9839 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9840 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9841 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9842 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9843 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9844 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9845 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9846 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9847 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9848 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9849 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9850 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9851 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9852 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9853 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9854 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9855 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9856 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9857 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9858 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9859 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9860 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9861 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9862 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9863 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9864 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9865 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9866 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9867 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9868 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9869 Shift Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9870 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9871 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9872 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9873 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9874 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9875 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS), Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9876 Shift Solenoid 1 (SS1) Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Shift Solenoid 2 (SS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9877 Shift Solenoid 3 (SS3) Shift Solenoid 3 (SS3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9878 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9881 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9882 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9883 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9884 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9885 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9886 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9887 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9888 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9893 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9896 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9897 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9898 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9899 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9900 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9901 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9902 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9903 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9904 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9905 Torque Converter Clutch Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9906 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9907 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9908 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9909 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9910 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9911 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9912 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9913 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9914 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9915 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9916 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9917 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9918 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9919 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9920 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9921 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9922 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9923 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9924 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9925 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9926 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9927 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9928 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9929 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9930 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9931 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9932 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9933 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9934 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9935 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9936 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9937 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9938 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9939 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9940 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9941 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9942 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9943 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9944 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9945 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9946 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9947 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9948 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9949 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9950 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9951 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9952 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9953 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9954 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9955 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9956 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9957 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9958 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 Torque Converter Clutch Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9967 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9968 Torque Converter Clutch Pulse Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9969 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9970 Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9971 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9974 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9975 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9976 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. Important: Removal of the valve body is not necessary for the following procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9977 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9978 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9979 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9980 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9981 Torque Converter Clutch Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9982 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9983 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9984 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 9985 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The instrument panel cluster (IPC) displays the selected gear position as determined by the powertrain control module (PCM). The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9997 Control Module: Diagrams Automatic Transmission Related Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9998 Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9999 Transmission Control Module (TCM) 80-Way Connector Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10000 Control Module: Service and Repair Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module (TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10001 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Connect the negative battery cable. 6. Reprogram the TCM. Refer to Control Module References in Computer/Integrating Systems. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10008 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10011 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10012 Fluid Pressure Sensor/Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10015 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10016 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Remove the remaining valve body bolts. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10017 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10018 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10019 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10020 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10021 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10022 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10023 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10024 Fluid Pressure Sensor/Switch: Service and Repair 4L80-E/4L85-E - Automatic Transmission Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel(r) Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body: ^ The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10025 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10026 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Remove the 8 checkballs (9 for some models). Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10027 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Install the manual 2-1 band servo piston (1). Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10028 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10029 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10030 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10031 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Tow/Haul Switch: Locations Automatic Transmission Electronic Component Views Transmission Control Module (MW7) Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Engine Harness to Transmission Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 10035 Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Tow/Haul Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10038 Tow/Haul Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10039 Tow/Haul Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Transmission Internal Mode Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > Page 10040 Tow/Haul Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 10044 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 10045 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10048 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10051 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10054 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10055 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10056 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10057 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10058 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10059 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10064 Transmission Speed Sensor: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Vehicle Speed Sensor Assembly, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10067 Transmission Speed Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10068 Automatic Transmission Output Speed Sensor (OSS) Automatic Transmission Output Speed Sensor (OSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10069 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10070 Automatic Transmission Turbine Speed Sensor Automatic Transmission Turbine Speed Sensor Vehicle Speed Sensor (VSS) Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10073 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10074 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10075 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10076 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10077 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10078 Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure 1. Be sure the vehicle ignition is turned off. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10079 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Install the speed sensor bolt (1). ^ Tighten bolt to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10084 Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10085 Transmission Temperature Sensor/Switch: Specifications Allison - Automatic Transmission Temperature vs Resistance (Transmission Fluid Temperature Sensor) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10086 Temperature vs Resistance (Speed Sensor) Temperature vs Resistance (Solenoid) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 10087 Transmission Temperature Sensor/Switch: Locations Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 10088 Transmission Temperature Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Transmission Fluid Temperature (TFT) Sensor, Wiring Harness Side Transmission Fluid Temperature (TFT) Sensor, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission Transmission Speed Sensor: Locations NV 3500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 10094 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 10095 Transmission Speed Sensor: Locations NV 4500 - Manual Transmission Manual Transmission Component Views Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 10096 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 10097 Transmission Speed Sensor: Locations ZF S6-650 - Manual Transmission Manual Transmission Component Views Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Clutch Pedal Position (CPP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 - Manual Transmission > Page 10098 1 - Clutch Pedal Position (CPP) Switch 2 - Dash Panel 3 - Clutch Pedal Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission Transmission Speed Sensor: Service and Repair NV 3500 - Manual Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 10101 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 10102 Transmission Speed Sensor: Service and Repair NV 4500 - Manual Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 10103 3. Connect the VSS electrical connector (3). Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 10104 Transmission Speed Sensor: Service and Repair ZF S6-650 - Manual Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 - Manual Transmission > Page 10105 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06505 > May > 06 > Campaign - PCM Software Update PROM - Programmable Read Only Memory: Recalls Campaign - PCM Software Update Subject: System Software Upgrade - OBD System Software Upgrade - OBD System Improvements (Reprogram Powertrain Control Module (PCM)) # 06505 - (05/15/2006) Models: 2006 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2006 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2006 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 2.5 for 2006 or later, broadcast to dealers on February 19, 2006; and on TIS CD-ROM version 3.0 / 2006 or later, mailed to dealers beginning on March 15, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06505 remains [Isquo ]open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or CD-ROM availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06505 > May > 06 > Campaign - PCM Software Update > Page 10114 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the "Select Programming Process" window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the "Validate Vehicle ID Number" screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the "Validate Vehicle ID Number" screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the "Select Programming Type" window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view "Summary" screen. 15. Verify that current and selected calibration information is displayed on the "Summary" screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-042B > Mar > 09 > Engine Controls - MIL ON/DTC's P2108/P1516/U0107 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P2108/P1516/U0107 TECHNICAL Bulletin No.: 06-06-04-042B Date: March 25, 2009 Subject: LM4, LM7, L59, LR4, LQ9, LQ4, LY6 Throttle Actuator Control (TAC) Module Codes, MIL/SES DTCs P2108, P1516, U0107, Reduced Engine Power (Reprogram PCM) Models: 2006 Cadillac Escalade Models 2006 Chevrolet Avalanche, Express 1500/2500/3500, Silverado, Silverado Flex Fuel, Silverado Hybrid, Silverado SS, Silverado 2500/3500 HD, Suburban, Tahoe 2006-2007 Chevrolet W3500/W4500 Series Medium Duty Tilt Cab 2006 GMC Savana 1500/2500/3500, Sierra, Sierra Flex Fuel, Sierra Hybrid, Sierra Performance Edition, Sierra 2500/3500 HD, Yukon Models 2006-2007 GMC W3500/4500 Series Medium Duty Tilt Cab 2006 HUMMER H2, H2 SUT All Equipped with GEN III or GEN IV Vortec 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U RPOs LR4, LM7, LM4, L59, LQ9, LQ4, LY6) Supercede: This bulletin is being revised to delete the 2007 model year and engines except for the 2007 MD 3500/4500 Tilt Cab Models. Please discard Corporate Bulletin Number 06-06-04-042A (Section 06 - Engine/Propulsion System). Condition Some customers may experience engine operation in the Reduced Engine Power mode, an MIL/SES light on and DTCs P2108, P1516, and U0107 set. Cause This condition may be caused by an error in the TAC Module communication software. Correction Diagnostics Aids: - Using the scan tool, check the Freeze Frame/Failure record for Engine Run Time and Vehicle Speed at the time the DTC occurred. If the above concern is encountered at start up and the vehicle speed is at zero, Do Not replace the TAC module for this condition. Refer to this bulletin for reprogramming the PCM. - If the Freeze Frame/Failure record indicates that the DTC occurred while driving, the condition may have been caused by static electricity resulting from improperly grounded equipment. If the vehicle has been upfitted with a ladder rack, utility bed or similar equipment, install a ground strap between the frame and the upfitted equipment, then evaluate repairs. If pulling a trailer, proper trailer grounds must be installed according to the instructions in the Owners Manual. - If the DTCs occur while the vehicle is in motion (speed greater than zero) and there is no apparent source of static electricity, proceed with diagnosis according to DTC P2108 service procedure in SI. PCM Reprogramming Instruction (if indicated from Diagnostic Aids) Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 8.5, which was broadcast to dealers on 08/20/2006. For the dealerships that use CDs, the CD version will be 8.5 for 2006, which will be mailed 08/24/2006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-042B > Mar > 09 > Engine Controls - MIL ON/DTC's P2108/P1516/U0107 > Page 10120 For vehicles repaired under the 8 year/80,000 miles (130,000 kilometers) emission controller warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - A/T Shudder/Slip in Reverse TECHNICAL Bulletin No.: 08-07-30-010 Date: February 27, 2008 Subject: 4L60E Automatic Transmission (RPO M30) - Shudder or Slip in Reverse Under Hard Acceleration (Reprogram PCM) Models: 2005-2006 Chevrolet Avalanche, Suburban Tahoe 2005-2007 Chevrolet Silverado Classic 2005-2006 GMC Yukon, Yukon XL 2005-2007 GMC Sierra Classic with 4.8L or 5.3L Engine and 4L60E Automatic Transmission (RPO M30) Condition Some customers may comment on a shudder or slip when engaging reverse on hard acceleration only. This condition is most easily duplicated by shifting to reverse and immediately accelerating very aggressively on level ground less aggressively up a hill or with a heavy load. Correction Important: Ensure the vehicle is equipped with the OEM tire size prior to attempting the below diagnosis. Also, make sure that the rear tires are matching side-to-side in make, size and depth of tread (wear). Mismatched tires can contribute to axle hop that can feel like shudder. Before attempting to duplicate this concern ask the customer if the condition occurs when the vehicle is loaded or has a trailer attached or if the vehicle is unloaded. This condition can also be caused by rear axle hop especially when backing a trailer up a hill. When attempting to duplicate the condition have another person watch the rear tires to verify a possible hop condition. Also when attempting to duplicate the condition allow one second after moving the shift lever to the reverse position before depressing the accelerator pedal. Increasing throttle before one second may result in slip or shudder even though there is not a problem with the transmission as the clutches are not fully filled and applied. If slip or shudder occurs verify that reverse boost can be obtained. Use a line pressure gauge to monitor line pressure and a Tech 2(R) to monitor PSC amperage during the concern and document in a TAC case. Engage D4 raise the engine RPM to 1000 and allow three seconds for line pressure to stabilize. Record the line pressure. Engage reverse raise engine the RPM to 1000 and allow three seconds for line pressure to stabilize and record line pressure again. Reverse pressure should be at least 20 psi (138 kPa) higher than drive pressure. Find an identical vehicle and duplicate the same driving maneuver. If it does exhibit the same symptom this may be an unreasonable driving maneuver and repairs may not be necessary. If another vehicle does not exhibit this concern the PCM should be reprogrammed. A revised transmission calibration has been developed to address these issues. Reprogram the PCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the latest software version. Important: These calibrations will be "selectable" and should only be used to correct a customer concern as detailed above. Use of this calibration in a vehicle without these concerns may result in comments of harsh engagement into reverse. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse > Page 10125 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10131 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10132 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10133 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10138 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10139 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10140 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-042B > Mar > 09 > Engine Controls - MIL ON/DTC's P2108/P1516/U0107 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2108/P1516/U0107 TECHNICAL Bulletin No.: 06-06-04-042B Date: March 25, 2009 Subject: LM4, LM7, L59, LR4, LQ9, LQ4, LY6 Throttle Actuator Control (TAC) Module Codes, MIL/SES DTCs P2108, P1516, U0107, Reduced Engine Power (Reprogram PCM) Models: 2006 Cadillac Escalade Models 2006 Chevrolet Avalanche, Express 1500/2500/3500, Silverado, Silverado Flex Fuel, Silverado Hybrid, Silverado SS, Silverado 2500/3500 HD, Suburban, Tahoe 2006-2007 Chevrolet W3500/W4500 Series Medium Duty Tilt Cab 2006 GMC Savana 1500/2500/3500, Sierra, Sierra Flex Fuel, Sierra Hybrid, Sierra Performance Edition, Sierra 2500/3500 HD, Yukon Models 2006-2007 GMC W3500/4500 Series Medium Duty Tilt Cab 2006 HUMMER H2, H2 SUT All Equipped with GEN III or GEN IV Vortec 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U RPOs LR4, LM7, LM4, L59, LQ9, LQ4, LY6) Supercede: This bulletin is being revised to delete the 2007 model year and engines except for the 2007 MD 3500/4500 Tilt Cab Models. Please discard Corporate Bulletin Number 06-06-04-042A (Section 06 - Engine/Propulsion System). Condition Some customers may experience engine operation in the Reduced Engine Power mode, an MIL/SES light on and DTCs P2108, P1516, and U0107 set. Cause This condition may be caused by an error in the TAC Module communication software. Correction Diagnostics Aids: - Using the scan tool, check the Freeze Frame/Failure record for Engine Run Time and Vehicle Speed at the time the DTC occurred. If the above concern is encountered at start up and the vehicle speed is at zero, Do Not replace the TAC module for this condition. Refer to this bulletin for reprogramming the PCM. - If the Freeze Frame/Failure record indicates that the DTC occurred while driving, the condition may have been caused by static electricity resulting from improperly grounded equipment. If the vehicle has been upfitted with a ladder rack, utility bed or similar equipment, install a ground strap between the frame and the upfitted equipment, then evaluate repairs. If pulling a trailer, proper trailer grounds must be installed according to the instructions in the Owners Manual. - If the DTCs occur while the vehicle is in motion (speed greater than zero) and there is no apparent source of static electricity, proceed with diagnosis according to DTC P2108 service procedure in SI. PCM Reprogramming Instruction (if indicated from Diagnostic Aids) Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 8.5, which was broadcast to dealers on 08/20/2006. For the dealerships that use CDs, the CD version will be 8.5 for 2006, which will be mailed 08/24/2006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-042B > Mar > 09 > Engine Controls - MIL ON/DTC's P2108/P1516/U0107 > Page 10145 For vehicles repaired under the 8 year/80,000 miles (130,000 kilometers) emission controller warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls A/T Shudder/Slip in Reverse TECHNICAL Bulletin No.: 08-07-30-010 Date: February 27, 2008 Subject: 4L60E Automatic Transmission (RPO M30) - Shudder or Slip in Reverse Under Hard Acceleration (Reprogram PCM) Models: 2005-2006 Chevrolet Avalanche, Suburban Tahoe 2005-2007 Chevrolet Silverado Classic 2005-2006 GMC Yukon, Yukon XL 2005-2007 GMC Sierra Classic with 4.8L or 5.3L Engine and 4L60E Automatic Transmission (RPO M30) Condition Some customers may comment on a shudder or slip when engaging reverse on hard acceleration only. This condition is most easily duplicated by shifting to reverse and immediately accelerating very aggressively on level ground less aggressively up a hill or with a heavy load. Correction Important: Ensure the vehicle is equipped with the OEM tire size prior to attempting the below diagnosis. Also, make sure that the rear tires are matching side-to-side in make, size and depth of tread (wear). Mismatched tires can contribute to axle hop that can feel like shudder. Before attempting to duplicate this concern ask the customer if the condition occurs when the vehicle is loaded or has a trailer attached or if the vehicle is unloaded. This condition can also be caused by rear axle hop especially when backing a trailer up a hill. When attempting to duplicate the condition have another person watch the rear tires to verify a possible hop condition. Also when attempting to duplicate the condition allow one second after moving the shift lever to the reverse position before depressing the accelerator pedal. Increasing throttle before one second may result in slip or shudder even though there is not a problem with the transmission as the clutches are not fully filled and applied. If slip or shudder occurs verify that reverse boost can be obtained. Use a line pressure gauge to monitor line pressure and a Tech 2(R) to monitor PSC amperage during the concern and document in a TAC case. Engage D4 raise the engine RPM to 1000 and allow three seconds for line pressure to stabilize. Record the line pressure. Engage reverse raise engine the RPM to 1000 and allow three seconds for line pressure to stabilize and record line pressure again. Reverse pressure should be at least 20 psi (138 kPa) higher than drive pressure. Find an identical vehicle and duplicate the same driving maneuver. If it does exhibit the same symptom this may be an unreasonable driving maneuver and repairs may not be necessary. If another vehicle does not exhibit this concern the PCM should be reprogrammed. A revised transmission calibration has been developed to address these issues. Reprogram the PCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the latest software version. Important: These calibrations will be "selectable" and should only be used to correct a customer concern as detailed above. Use of this calibration in a vehicle without these concerns may result in comments of harsh engagement into reverse. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse > Page 10150 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06505 > May > 06 > Campaign - PCM Software Update PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - PCM Software Update Subject: System Software Upgrade - OBD System Software Upgrade - OBD System Improvements (Reprogram Powertrain Control Module (PCM)) # 06505 - (05/15/2006) Models: 2006 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2006 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2006 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 2.5 for 2006 or later, broadcast to dealers on February 19, 2006; and on TIS CD-ROM version 3.0 / 2006 or later, mailed to dealers beginning on March 15, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06505 remains [Isquo ]open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or CD-ROM availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06505 > May > 06 > Campaign - PCM Software Update > Page 10155 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the "Select Programming Process" window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the "Validate Vehicle ID Number" screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the "Validate Vehicle ID Number" screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the "Select Programming Type" window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view "Summary" screen. 15. Verify that current and selected calibration information is displayed on the "Summary" screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10161 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10162 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10163 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10168 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10169 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10170 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-042B > Mar > 09 > Engine Controls - MIL ON/DTC's P2108/P1516/U0107 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2108/P1516/U0107 TECHNICAL Bulletin No.: 06-06-04-042B Date: March 25, 2009 Subject: LM4, LM7, L59, LR4, LQ9, LQ4, LY6 Throttle Actuator Control (TAC) Module Codes, MIL/SES DTCs P2108, P1516, U0107, Reduced Engine Power (Reprogram PCM) Models: 2006 Cadillac Escalade Models 2006 Chevrolet Avalanche, Express 1500/2500/3500, Silverado, Silverado Flex Fuel, Silverado Hybrid, Silverado SS, Silverado 2500/3500 HD, Suburban, Tahoe 2006-2007 Chevrolet W3500/W4500 Series Medium Duty Tilt Cab 2006 GMC Savana 1500/2500/3500, Sierra, Sierra Flex Fuel, Sierra Hybrid, Sierra Performance Edition, Sierra 2500/3500 HD, Yukon Models 2006-2007 GMC W3500/4500 Series Medium Duty Tilt Cab 2006 HUMMER H2, H2 SUT All Equipped with GEN III or GEN IV Vortec 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U RPOs LR4, LM7, LM4, L59, LQ9, LQ4, LY6) Supercede: This bulletin is being revised to delete the 2007 model year and engines except for the 2007 MD 3500/4500 Tilt Cab Models. Please discard Corporate Bulletin Number 06-06-04-042A (Section 06 - Engine/Propulsion System). Condition Some customers may experience engine operation in the Reduced Engine Power mode, an MIL/SES light on and DTCs P2108, P1516, and U0107 set. Cause This condition may be caused by an error in the TAC Module communication software. Correction Diagnostics Aids: - Using the scan tool, check the Freeze Frame/Failure record for Engine Run Time and Vehicle Speed at the time the DTC occurred. If the above concern is encountered at start up and the vehicle speed is at zero, Do Not replace the TAC module for this condition. Refer to this bulletin for reprogramming the PCM. - If the Freeze Frame/Failure record indicates that the DTC occurred while driving, the condition may have been caused by static electricity resulting from improperly grounded equipment. If the vehicle has been upfitted with a ladder rack, utility bed or similar equipment, install a ground strap between the frame and the upfitted equipment, then evaluate repairs. If pulling a trailer, proper trailer grounds must be installed according to the instructions in the Owners Manual. - If the DTCs occur while the vehicle is in motion (speed greater than zero) and there is no apparent source of static electricity, proceed with diagnosis according to DTC P2108 service procedure in SI. PCM Reprogramming Instruction (if indicated from Diagnostic Aids) Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 8.5, which was broadcast to dealers on 08/20/2006. For the dealerships that use CDs, the CD version will be 8.5 for 2006, which will be mailed 08/24/2006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-042B > Mar > 09 > Engine Controls - MIL ON/DTC's P2108/P1516/U0107 > Page 10175 For vehicles repaired under the 8 year/80,000 miles (130,000 kilometers) emission controller warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls A/T Shudder/Slip in Reverse TECHNICAL Bulletin No.: 08-07-30-010 Date: February 27, 2008 Subject: 4L60E Automatic Transmission (RPO M30) - Shudder or Slip in Reverse Under Hard Acceleration (Reprogram PCM) Models: 2005-2006 Chevrolet Avalanche, Suburban Tahoe 2005-2007 Chevrolet Silverado Classic 2005-2006 GMC Yukon, Yukon XL 2005-2007 GMC Sierra Classic with 4.8L or 5.3L Engine and 4L60E Automatic Transmission (RPO M30) Condition Some customers may comment on a shudder or slip when engaging reverse on hard acceleration only. This condition is most easily duplicated by shifting to reverse and immediately accelerating very aggressively on level ground less aggressively up a hill or with a heavy load. Correction Important: Ensure the vehicle is equipped with the OEM tire size prior to attempting the below diagnosis. Also, make sure that the rear tires are matching side-to-side in make, size and depth of tread (wear). Mismatched tires can contribute to axle hop that can feel like shudder. Before attempting to duplicate this concern ask the customer if the condition occurs when the vehicle is loaded or has a trailer attached or if the vehicle is unloaded. This condition can also be caused by rear axle hop especially when backing a trailer up a hill. When attempting to duplicate the condition have another person watch the rear tires to verify a possible hop condition. Also when attempting to duplicate the condition allow one second after moving the shift lever to the reverse position before depressing the accelerator pedal. Increasing throttle before one second may result in slip or shudder even though there is not a problem with the transmission as the clutches are not fully filled and applied. If slip or shudder occurs verify that reverse boost can be obtained. Use a line pressure gauge to monitor line pressure and a Tech 2(R) to monitor PSC amperage during the concern and document in a TAC case. Engage D4 raise the engine RPM to 1000 and allow three seconds for line pressure to stabilize. Record the line pressure. Engage reverse raise engine the RPM to 1000 and allow three seconds for line pressure to stabilize and record line pressure again. Reverse pressure should be at least 20 psi (138 kPa) higher than drive pressure. Find an identical vehicle and duplicate the same driving maneuver. If it does exhibit the same symptom this may be an unreasonable driving maneuver and repairs may not be necessary. If another vehicle does not exhibit this concern the PCM should be reprogrammed. A revised transmission calibration has been developed to address these issues. Reprogram the PCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the latest software version. Important: These calibrations will be "selectable" and should only be used to correct a customer concern as detailed above. Use of this calibration in a vehicle without these concerns may result in comments of harsh engagement into reverse. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse > Page 10180 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10186 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10187 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10188 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10193 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10194 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 10195 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06505 > May > 06 > Campaign - PCM Software Update PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - PCM Software Update Subject: System Software Upgrade - OBD System Software Upgrade - OBD System Improvements (Reprogram Powertrain Control Module (PCM)) # 06505 - (05/15/2006) Models: 2006 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2006 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2006 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 2.5 for 2006 or later, broadcast to dealers on February 19, 2006; and on TIS CD-ROM version 3.0 / 2006 or later, mailed to dealers beginning on March 15, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06505 remains [Isquo ]open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or CD-ROM availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06505 > May > 06 > Campaign - PCM Software Update > Page 10200 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the "Select Programming Process" window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the "Validate Vehicle ID Number" screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the "Validate Vehicle ID Number" screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the "Select Programming Type" window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view "Summary" screen. 15. Verify that current and selected calibration information is displayed on the "Summary" screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10208 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10209 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10210 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10211 Clutch Control Solenoid Valve: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10212 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10213 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10214 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10215 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10220 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison Automatic Transmission > Page 10223 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Control Solenoid 2 (PCS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison Automatic Transmission > Page 10224 Pressure Switch Manifold (PSM) Pressure Switch Manifold (PSM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison Automatic Transmission > Page 10225 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison Automatic Transmission > Page 10226 Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison Automatic Transmission > Page 10227 Pressure Regulating Solenoid: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid Valve, Wiring Harness Side Pressure Control Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10230 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10231 Pressure Regulating Solenoid: Service and Repair 4L80-E/4L85-E - Automatic Transmission Pressure Regulator Replacement ^ Tools Required J 36850 Transjel(r) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the transmission filter. 3. Remove the reverse boost valve bushing retainer ring (2). Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10232 2. Pre-assemble the following parts: ^The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 10236 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission Shift Solenoid Valve State And Gear Ratio 4L60-E/4L70-E Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 10241 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission Shift Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 10244 Shift Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10247 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10248 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10249 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10250 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10251 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10252 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10253 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10254 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10255 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10256 Shift Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10257 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10258 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10277 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10278 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10279 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10280 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10281 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10282 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10283 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10284 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10285 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10286 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10287 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10288 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10289 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10290 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10291 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10301 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10302 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10303 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10304 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10305 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10306 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10307 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10308 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10309 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10310 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10311 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10312 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10313 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10314 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10315 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10316 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10317 Shift Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10318 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10319 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10320 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10321 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10322 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10323 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS), Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10324 Shift Solenoid 1 (SS1) Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Shift Solenoid 2 (SS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10325 Shift Solenoid 3 (SS3) Shift Solenoid 3 (SS3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10326 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10329 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10330 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10331 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10332 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10333 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10334 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10335 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10336 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10341 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10344 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10345 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10346 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10347 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10348 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10349 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10350 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10351 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10352 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10353 Torque Converter Clutch Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10354 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10355 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10356 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10357 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10358 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10359 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10360 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10361 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10362 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10363 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10364 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10365 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10366 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10367 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10368 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10369 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10370 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10371 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10372 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10373 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10374 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10375 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10376 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10377 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10378 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10379 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10380 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10381 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10382 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10383 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10384 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10385 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10386 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10387 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10388 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10389 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10390 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10391 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10392 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10393 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10394 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10395 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10396 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10397 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10398 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10399 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10400 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10401 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10402 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10403 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10404 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10405 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10406 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10407 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10408 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10409 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10410 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10411 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10412 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10413 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10414 Torque Converter Clutch Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10415 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10416 Torque Converter Clutch Pulse Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10417 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10418 Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10419 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10422 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10423 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10424 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. Important: Removal of the valve body is not necessary for the following procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10425 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10426 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10427 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10428 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10429 Torque Converter Clutch Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10430 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10431 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10432 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10433 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10440 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10441 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10442 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10443 Clutch Control Solenoid Valve: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10444 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10445 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10446 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10447 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission Pressure Regulating Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 10452 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10455 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Control Solenoid 2 (PCS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10456 Pressure Switch Manifold (PSM) Pressure Switch Manifold (PSM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10457 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10458 Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10459 Pressure Regulating Solenoid: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid Valve, Wiring Harness Side Pressure Control Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10462 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10463 Pressure Regulating Solenoid: Service and Repair 4L80-E/4L85-E - Automatic Transmission Pressure Regulator Replacement ^ Tools Required J 36850 Transjel(r) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the transmission filter. 3. Remove the reverse boost valve bushing retainer ring (2). Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10464 2. Pre-assemble the following parts: ^The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 10468 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State And Gear Ratio 4L60-E/4L70-E Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10473 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10476 Shift Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10479 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10480 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10481 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10482 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10483 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10484 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10485 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 Shift Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10496 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10497 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10498 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10499 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10500 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10501 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10502 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10503 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10504 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10505 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10506 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10507 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10508 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10509 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10510 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10511 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10512 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10513 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10514 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10515 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10516 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10517 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10518 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10519 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10520 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10521 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10522 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10523 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10524 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10525 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10526 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10527 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10528 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10529 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10530 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10531 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10532 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10533 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10534 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10535 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10536 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10537 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10538 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10539 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10540 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10541 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10542 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10543 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10544 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10545 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10546 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10547 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10548 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10549 Shift Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10550 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10551 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10552 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10553 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10554 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10555 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS), Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10556 Shift Solenoid 1 (SS1) Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Shift Solenoid 2 (SS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10557 Shift Solenoid 3 (SS3) Shift Solenoid 3 (SS3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10558 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10561 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10562 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10563 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10564 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10565 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10566 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10567 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10568 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 10573 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10576 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10577 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10578 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10579 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10580 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10581 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10582 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10583 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 Torque Converter Clutch Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10586 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10587 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10588 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10589 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10593 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10594 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10595 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10599 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10600 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 - Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10601 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10602 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10603 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10604 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10605 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10606 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10607 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10608 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10609 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10610 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10611 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10612 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10613 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10614 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10615 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10616 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10617 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10618 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10619 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10620 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10621 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10622 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10623 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10624 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10625 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10626 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10627 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10628 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10629 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10630 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10631 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10632 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10633 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10634 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10635 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10636 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10637 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10638 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10639 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10640 IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10641 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10642 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10643 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10644 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10645 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10646 Torque Converter Clutch Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10647 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10648 Torque Converter Clutch Pulse Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10649 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10650 Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10651 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10654 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10655 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10656 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. Important: Removal of the valve body is not necessary for the following procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10657 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10658 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10659 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10660 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10661 Torque Converter Clutch Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10662 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10663 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10664 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10665 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 10670 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 10671 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 10672 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Accumulator: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Remove the transmission filter. 2. Remove the valve body. Important: The 1-2 accumulator can be removed without removing the valve body. 3. Remove the accumulator cover bolts. 4. Remove the 1-2 accumulator cover. 5. Remove the 1-2 accumulator cover (57) and pin. Important: Regular production option (RPO) M33 transmissions do not use a 1-2 accumulator spring inner (104). 6. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104). 7. Inspect the 1-2 accumulator springs for cracks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10675 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support bolts. 12. Remove the spacer plate support. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10676 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10677 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10678 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. 10. Install the spacer plate support and the spacer plate support bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10679 13. Assemble the 1-2 accumulator assembly (54, 56, 57, 104). Ensure that the piston legs face the accumulator cover. Important: RPO M33 transmissions do not use a 1-2 accumulator spring inner (104). 14. Install the 1-2 accumulator cover (57) and pin. 15. Install the 1-2 accumulator cover and the accumulator cover bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the valve body. 18. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10680 Accumulator: Service and Repair 4L80-E/4L85-E - Automatic Transmission Accumulator Housing Replacement ^ Tools Required J 25025-5 Valve Body Align Pin Removal Procedure 1. Remove the valve body. 2. Remove the 3rd and 4th clutch accumulator housing bolts (1). 3. Remove the 3rd and 4th clutch accumulator housing (8). 4. Remove the accumulator housing gasket (6). The accumulator housing gasket may be stuck to the spacer plate (5). 5. Remove the 3rd clutch accumulator piston spring (7). 6. Remove the 4th clutch accumulator piston spring (2). 7. Remove the valve body spacer plate (5). 8. Remove the valve body to spacer plate gasket (4) from the spacer plate (5). Third and Fourth Clutch Accumulator Disassembly 1. Remove the 3rd clutch accumulator piston (2). Important: Apply low pressure compressed air to the hole at the top of the accumulator housing to assist with the piston removal. 2. Remove the 3rd clutch accumulator piston seals (1, 3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10681 3. Remove the 4th clutch accumulator piston pin retainer ring (5). 4. Remove the 4th clutch accumulator piston (4) and pin (2) from the accumulator housing (1). 5. Remove the 4th clutch accumulator piston pin (2) from the accumulator housing (1). 6. Remove the 4th clutch accumulator piston seal (3) from the accumulator housing (1). Third and Fourth Clutch Accumulator Assembly 1. Install the 3rd clutch accumulator piston inner (3) and outer (1) seals. Lubricate the 3rd clutch accumulator piston seals (1, 3) with DEXRON(r) III automatic transmission fluid. 2. Install the 3rd clutch accumulator piston (2). 3. Install the 4th clutch accumulator piston seal (3). Lubricate the 4th clutch accumulator piston seal (3) with DEXRON(r) III automatic transmission fluid. 4. Assemble the 4th clutch accumulator piston pin (2) with the 4th clutch accumulator piston (4). 5. Install the 4th clutch accumulator piston assembly into the accumulator housing (1). 6. Install the 4th clutch accumulator piston pin retainer ring (5) onto the 4th clutch accumulator piston pin (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10682 1. Install J 25025 into the valve body bolt hole where the manual shaft detent roller and spring is mounted. 2. Install the valve body gasket (2) onto the accumulator housing (1). 3. Install the valve body spacer plate (3) onto the valve body gasket (2). 4. Install the third and fourth clutch accumulator housing gasket (3). 5. Install the third clutch accumulator piston spring (1). This spring is the longer of the two springs. 6. Install the fourth clutch accumulator piston spring (4). 7. Install the third and fourth clutch accumulator housing assembly (5) onto the control valve body assembly (2). 8. Install the six accumulator housing bolts (6). Start the bolts finger tight and work towards the opposite end. 9.Tighten the accumulator housing bolts sequentially. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 10. Remove the J 25025. 11. Install the valve body. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Band Apply Servo: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission 2-4 Servo ^ Tools Required J 29714-A Servo Cover Depressor Removal Procedure 1. Remove the exhaust pipe. 2. Remove the heat shield bolts. 3. Remove the heat shield. 4. Remove the oil pan bolt below the servo. 5. Install the J 29714-A. 6. Tighten the bolt on J 29714-A in order to compress the servo cover. 7. Remove the servo cover ring. 8. Remove the J 29714-A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10687 9. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 10. Remove the 2-4 servo. 11. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install NEW seals onto the servo pistons and the servo cover. 2. Install the 2-4 servo. 3. Install the J 29714-A. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10688 4. ^ Tighten the bolt on J 29714-A in order to compress the servo cover. 5. Install the servo cover ring. 6. Remove the J 29714-A. 7. Install the oil pan bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 8. Install the heat shield and bolts. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 9. Install the exhaust pipe. 10. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10689 Band Apply Servo: Service and Repair 4L80-E/4L85-E - Automatic Transmission Reverse Servo Replacement Reverse Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the rear servo from the transmission case in the following order: 1. Cover bolts (6) 2. Cover (5) 3. Cover gasket (4) 4. Bottom retaining clip (3) 5. Servo piston (2) 6. Outer ring oil seal (1) 7. Inner ring oil seal (7) 8. Accumulator piston (8) 9. Piston seal (9) 10. Washer (10) 11. Servo spring (11) 12. Servo spring retainer (12) 13. Selective pin (13) 14. Accumulator spring (14) Installation Procedure 1. Install the rear servo to the transmission in the following order: 1. Accumulator spring (14) 2. Selective pin (13) 3. Servo spring retainer (12) 4. Servo spring (11) 5. Washer (10) 6. Piston seal (9) 7. Accumulator piston (8) 8. Inner ring oil seal (7) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10690 9. Outer ring oil seal (1) 10. Servo piston (2) 11. Bottom retaining clip (3) 12. Cover gasket (4) 13. Cover (5) 14. Cover bolts (6) Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the cover bolts (61). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Forward Servo Replacement Forward Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the forward servo cover bolts, cover, and gasket. 3. Remove the following parts: 1. Forward servo piston pin (5) 2. O-ring seal (4) 3. Servo piston (3) 4. Retainer (2) 5. Piston spring (1) Installation Procedure 1. Install the following parts: ^ Piston spring (1) ^ Retainer (2) ^ Servo piston (3) ^ O-ring seal (4) ^ Forward servo piston pin (5) Notice: Refer to Fastener Notice in Service Precautions. 2. Install the forward servo gasket, cover, and bolts. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10691 ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 10696 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 10705 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-032E > Sep > 08 > A/T 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-032E > Sep > 08 > A/T 4T65E Fluid Leaking From A/T Vent > Page 10715 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10721 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10722 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10723 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10729 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10730 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10731 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 10740 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 10741 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 10751 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 10752 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-015 > Mar > 08 > A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Clutch: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 08-07-30-015 > Mar > 08 > A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Clutch: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10770 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10771 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10772 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10773 Clutch Control Solenoid Valve: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10774 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10775 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10776 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10777 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10782 Control Module: Diagrams Automatic Transmission Related Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10783 Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10784 Transmission Control Module (TCM) 80-Way Connector Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10785 Control Module: Service and Repair Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module (TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10786 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Connect the negative battery cable. 6. Reprogram the TCM. Refer to Control Module References in Computer/Integrating Systems. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > Customer Interest for Differential: > 08-07-30-016A > Apr > 08 > A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894 Differential: Customer Interest A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894 INFORMATION Bulletin No.: 08-07-30-016A Date: April 15, 2008 Subject: Diagnostic Information on MH1, MN8, MT1, M15 Transmission Slips, Will Not Shift or May Overheat, SES/MIL May be Illuminated, DTCs P0218, P0894 Set Models: 2006-2007 Buick Rendezvous, Terraza 2006-2008 Buick LaCrosse, Lucerne, Allure (Canada Only) 2008 Buick LaCrosse Super, Lucerne Super, Allure Super (Canada Only) 2006-2007 Cadillac DTS 2006-2007 Chevrolet Avalanche 2500 Series, Malibu, Malibu SS, Malibu Maxx SS, Monte Carlo, Monte Carlo SS, Silverado Classic, Suburban 2006-2008 Chevrolet Express, Impala, Impala SS, Uplander 2006-2007 GMC Sierra Classic, Yukon XL 2500 Series 2006-2008 GMC Savana 2006-2008 Pontiac Grand Prix, Grand Prix GTP, Grand Prix GXP, G6, Montana SV6 2006-2007 Saturn Relay with HYDRA‐MATIC(R) 4T80‐E (MH1), 4T65‐E (M15), 4L80E (RPO MT1) or 4L85E (RPO MN8) Automatic Transmission Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 08-07-30-016 (Section 07 - Transmission/Transaxle). Notice: It is critical that all internal transmission components are thoroughly cleaned and the transmission cooler be flushed using the J 45096 transmission oil cooling system flush and flow test tool. It is also critical that the system be flushed in both directions to capture any friction material trapped in the cooler. Be sure to back-flush first to push material out of the cooler, following the instructions provided with the J 45096. The purpose of the bulletin is to provide technicians with additional diagnostic information on transmission slips, will not shift, or may overheat conditions. DTCs P0894 or P0218 may be set on the above transmissions. These conditions may be caused by friction material debonding from the Torque Converter Clutch (TCC). If any of these conditions are observed, the friction material from the TCC may have circulated throughout the transmission, the cooler lines, and the transmission cooler. Remove the transmission oil pan and inspect for friction material in the filter. If friction material is observed in the trans pan or filter, the torque converter is the possible cause and it will be necessary to disassemble the transmission completely for a cost comparison (include a torque converter and filter in the estimate). Refer to service bulletin 08-07-30-001 for cleaning and inspection instructions of the valve body assembly. After the cost comparison, either repair or replace the transmission in the most cost effective way. If it is necessary to replace the transmission, contact the Product Quality Center (PQC) per the most recent version of bulletin 02-07-30-029. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential: > 08-07-30-016A > Apr > 08 > A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894 Differential: All Technical Service Bulletins A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894 INFORMATION Bulletin No.: 08-07-30-016A Date: April 15, 2008 Subject: Diagnostic Information on MH1, MN8, MT1, M15 Transmission Slips, Will Not Shift or May Overheat, SES/MIL May be Illuminated, DTCs P0218, P0894 Set Models: 2006-2007 Buick Rendezvous, Terraza 2006-2008 Buick LaCrosse, Lucerne, Allure (Canada Only) 2008 Buick LaCrosse Super, Lucerne Super, Allure Super (Canada Only) 2006-2007 Cadillac DTS 2006-2007 Chevrolet Avalanche 2500 Series, Malibu, Malibu SS, Malibu Maxx SS, Monte Carlo, Monte Carlo SS, Silverado Classic, Suburban 2006-2008 Chevrolet Express, Impala, Impala SS, Uplander 2006-2007 GMC Sierra Classic, Yukon XL 2500 Series 2006-2008 GMC Savana 2006-2008 Pontiac Grand Prix, Grand Prix GTP, Grand Prix GXP, G6, Montana SV6 2006-2007 Saturn Relay with HYDRA‐MATIC(R) 4T80‐E (MH1), 4T65‐E (M15), 4L80E (RPO MT1) or 4L85E (RPO MN8) Automatic Transmission Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 08-07-30-016 (Section 07 - Transmission/Transaxle). Notice: It is critical that all internal transmission components are thoroughly cleaned and the transmission cooler be flushed using the J 45096 transmission oil cooling system flush and flow test tool. It is also critical that the system be flushed in both directions to capture any friction material trapped in the cooler. Be sure to back-flush first to push material out of the cooler, following the instructions provided with the J 45096. The purpose of the bulletin is to provide technicians with additional diagnostic information on transmission slips, will not shift, or may overheat conditions. DTCs P0894 or P0218 may be set on the above transmissions. These conditions may be caused by friction material debonding from the Torque Converter Clutch (TCC). If any of these conditions are observed, the friction material from the TCC may have circulated throughout the transmission, the cooler lines, and the transmission cooler. Remove the transmission oil pan and inspect for friction material in the filter. If friction material is observed in the trans pan or filter, the torque converter is the possible cause and it will be necessary to disassemble the transmission completely for a cost comparison (include a torque converter and filter in the estimate). Refer to service bulletin 08-07-30-001 for cleaning and inspection instructions of the valve body assembly. After the cost comparison, either repair or replace the transmission in the most cost effective way. If it is necessary to replace the transmission, contact the Product Quality Center (PQC) per the most recent version of bulletin 02-07-30-029. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Application and ID Extension Housing: Application and ID Case Extension Identification 1 - Case Extension - used on C-Truck, G-Van, S-Truck 2 - Case Extension - Some Models Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Extension Housing: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10805 Extension Housing: Service and Repair 4L80-E/4L85-E - Automatic Transmission Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission support and the transmission mount. 6. Remove the case extension bolts (3). 7. Remove the case extension (1). 8. Remove and discard the case extension O ring seal (2). Installation Procedure 1. Install a new case extension O ring seal (2). 2. Install the case extension (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (3). ^ Tighten the bolts (3) to 34 Nm (25 ft. lbs.). 4. Install the transmission support and the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 10810 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 10811 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 10812 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E/4L65-E/4L70-E Pan Removal ................................................................................................. .................................................................................................... 4.7L (5.0 Qt) Overhaul .................... .............................................................................................................................................................. ...................... 10.6L (11.0 Qt) 4L80-E/4L85-E Dry .............................................................................................................................. .................................................................................. 12.8L (13.5 Qt) Pan Removal ........................... .............................................................................................................................................................. ............ 7.3L (7.7 Qt) Allison Overhaul .................................................................................................................................. ...................................................................... 12.0L (12.7 Qt) Fluid Change ....................................... .............................................................................................................................................................. 7.0L (7.4 Qt) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 10815 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure Fluid - A/T: Testing and Inspection Allison Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Cold Fluid Check The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. 1. Bring the vehicle to a complete stop on a level surface using the service brakes. Important: The fluid level rises as fluid temperature increases. DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 2. Ensure that the engine is at low idle RPM (500-800 RPM). 3. With the service brakes applied, put the transmission in the P, PARK, position. 4. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 5. Apply the parking brake and ensure it is properly engaged. 6. Run the engine for at least one minute. Apply the service brakes and shift to D, DRIVE, then to N, NEUTRAL, and then shift to R, REVERSE, in order to fill the hydraulic system. 7. Ensure that the engine is at low idle RPM (500-800 RPM). 8. With the service brakes applied, put the transmission in the P, PARK, position. 9. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 10. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 11. Insert the fluid level indicator into the fill tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. Important: ^ If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD CHECK band, add or drain as necessary to bring it to the middle of the COLD CHECK band. ^ Always check the fluid level at least twice using the procedure described above. Consistent readings are important in order to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure that it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 12. Perform a hot check at the first opportunity after the normal operating sump temperature of 71 93°C (160 - 200°F) is reached. Hot Fluid Check 1. Operate the transmission in D, DRIVE, range until normal operating temperature is reached. Normal operating temperature is any of the following: ^ Sump temperature 71 - 93°C (160 - 200°F) ^ Converter-out temperature 82 - 104°C (180 - 220°F) ^ If a transmission temperature gage is not present, check the fluid level when the engine water temperature gage has stabilized and the transmission has been operated under load for at least one hour. Important: The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases. 2. Bring the vehicle to a complete stop on a level surface using the service brake. 3. Ensure that the engine is at low idle RPM, 500-800 RPM. 4. With the service brakes applied, place the transmission in the P, PARK, position. 5. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 6. Apply the parking brake and ensure it is properly engaged. 7. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 8. Insert the fluid level indicator into fill the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading. Important: Always check the fluid level at least twice using the procedure described above. Consistent readings are important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 9. If the fluid level is not within the HOT RUN band, add or drain as necessary to bring the fluid level to within the HOT RUN band. Important: Safe operating level is within the HOT RUN band on the fluid level indicator. The width of the HOT RUN band represents approximately 1.0 liter (1.06 quarts) of fluid at normal operating sump temperature. Fluid Inspection Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 10818 1. Examine the drained fluid for evidence of dirt. Important: Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. High temperature causes the transmission fluid to be discolored or to have a strong odor. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. 2. Examine the drained fluid for evidence of water. Obvious water contamination of the transmission fluid or transmission fluid in the cooling water from the heat exchanger indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. Important: Cooler water may be contaminated by engine oil if an engine oil cooler is present; be sure to locate the correct source of cooler water contamination. 3. Examine the drained fluid for evidence of engine coolant. Notice: Engine coolant in the transmission hydraulic system requires immediate action. Failure to clean or replace all contaminated components may result in premature transmission failure. 4. Examine the drained fluid for evidence of metal. Metal particles in the fluid, other than minute particles normally trapped in the oil filter, indicate internal transmission damage. When this occurs, inspect the inside of the oil pan for excessive metal particles. 5. Metal contamination requires complete transmission disassembly. 6. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. Notice: Flush the transmission cooling system and inspect for restrictions following a transmission failure. Failure to repair or replace restricted oil cooling system components may result in premature transmission failure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 10819 Fluid - A/T: Testing and Inspection 4L60-E/4L65-E/4L70-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 10820 Step 1 - Step 17 Step 18 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 10821 Fluid - A/T: Testing and Inspection 4L80-E/4L85-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Allison Transmission Fluid Checking Procedure > Page 10822 Step 1 - Step 15 Step 16 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10825 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10826 4. Install the oil pan and NEW gasket. 5. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10827 Step 1 - Step 17 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10828 Step 18 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10829 Fluid - A/T: Service and Repair 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10830 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). 14. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. Important: It is not necessary to remove the selector cable from the bracket. 15. Remove the oil pan bolts. 16. Remove the oil pan and gasket. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 17. Remove the magnet from the bottom of the pan, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10831 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10832 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10833 Step 1 - Step 15 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10834 Step 16 - Step 20 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82 - 93°C (180 - 200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10835 Fluid - A/T: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 2. Inspect the drained fluid. 3. Remove the filter (4) by rotating in the counterclockwise direction. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Install the drain plug (6) and drain plug seal (5). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10836 6. Refill Transmission with DEXRON(r)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. 7. Cycle the ignition until Drive or Reverse range is attained. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. 8. Check the transmission fluid level. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Cold Fluid Check The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. 1. Bring the vehicle to a complete stop on a level surface using the service brakes. Important: The fluid level rises as fluid temperature increases. DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 2. Ensure that the engine is at low idle RPM (500-800 RPM). 3. With the service brakes applied, put the transmission in the P, PARK, position. 4. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 5. Apply the parking brake and ensure it is properly engaged. 6. Run the engine for at least one minute. Apply the service brakes and shift to D, DRIVE, then to N, NEUTRAL, and then shift to R, REVERSE, in order to fill the hydraulic system. 7. Ensure that the engine is at low idle RPM (500-800 RPM). 8. With the service brakes applied, put the transmission in the P, PARK, position. 9. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 10. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 11. Insert the fluid level indicator into the fill tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. Important: ^ If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD CHECK band, add or drain as necessary to bring it to the middle of the COLD CHECK band. ^ Always check the fluid level at least twice using the procedure described above. Consistent readings are important in order to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure that it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 12. Perform a hot check at the first opportunity after the normal operating sump temperature of 71 93°C (160 - 200°F) is reached. Hot Fluid Check 1. Operate the transmission in D, DRIVE, range until normal operating temperature is reached. Normal operating temperature is any of the following: ^ Sump temperature 71 - 93°C (160 - 200°F) ^ Converter-out temperature 82 - 104°C (180 - 220°F) ^ If a transmission temperature gage is not present, check the fluid level when the engine water temperature gage has stabilized and the transmission has been operated under load for at least one hour. Important: The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases. 2. Bring the vehicle to a complete stop on a level surface using the service brake. 3. Ensure that the engine is at low idle RPM, 500-800 RPM. 4. With the service brakes applied, place the transmission in the P, PARK, position. 5. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 6. Apply the parking brake and ensure it is properly engaged. 7. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. 8. Insert the fluid level indicator into fill the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10837 Important: Always check the fluid level at least twice using the procedure described above. Consistent readings are important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 9. If the fluid level is not within the HOT RUN band, add or drain as necessary to bring the fluid level to within the HOT RUN band. Important: Safe operating level is within the HOT RUN band on the fluid level indicator. The width of the HOT RUN band represents approximately 1.0 liter (1.06 quarts) of fluid at normal operating sump temperature. Fluid Inspection 1. Examine the drained fluid for evidence of dirt. Important: Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. High temperature causes the transmission fluid to be discolored or to have a strong odor. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. 2. Examine the drained fluid for evidence of water. Obvious water contamination of the transmission fluid or transmission fluid in the cooling water from the heat exchanger indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. Important: Cooler water may be contaminated by engine oil if an engine oil cooler is present; be sure to locate the correct source of cooler water contamination. 3. Examine the drained fluid for evidence of engine coolant. Notice: Engine coolant in the transmission hydraulic system requires immediate action. Failure to clean or replace all contaminated components may result in premature transmission failure. 4. Examine the drained fluid for evidence of metal. Metal particles in the fluid, other than minute particles normally trapped in the oil filter, indicate internal transmission damage. When this occurs, inspect the inside of the oil pan for excessive metal particles. 5. Metal contamination requires complete transmission disassembly. 6. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. Notice: Flush the transmission cooling system and inspect for restrictions following a transmission failure. Failure to repair or replace restricted oil cooling system components may result in premature transmission failure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10842 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10843 4. Install the oil pan and NEW gasket. 5. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10844 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10845 14. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. Important: It is not necessary to remove the selector cable from the bracket. 15. Remove the oil pan bolts. 16. Remove the oil pan and gasket. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10846 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.) 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.) 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10847 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10848 Fluid Filter - A/T: Service and Repair Allison - Automatic Transmission Transmission Fluid Filter Adapter Replacement Transmission Fluid Filter Adapter Replacement Removal Procedure 1. Remove the transmission external oil filter (4) by rotating in the counterclockwise direction. Important: ^ DO NOT drain the fluid if only the transmission external oil filter adapter is being replaced. ^ Use a standard strap-type filter wrench to remove or install the transmission external oil filter. 2. Remove the magnet (2) from the transmission external oil filter adapter (1) in the converter housing or from the filter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 4. Remove the filter adapter (1) from the converter housing. Installation Procedure 1. Install the transmission external oil filter adapter (1). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the adapter to 30 Nm (22 ft. lbs.). 2. Reinstall the magnet (2) onto the filter adapter (1). 3. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 4. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. Turn the filter ONE FULL TURN ONLY after gasket contact. 5. Check the transmission fluid level. 6. Notice: Use only clean and approved transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10849 Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 2. Inspect the drained fluid. 3. Remove the filter (4) by rotating in the counterclockwise direction. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Install the drain plug (6) and drain plug seal (5). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Refill Transmission with DEXRON(r)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. 7. Cycle the ignition until Drive or Reverse range is attained. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10850 Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. 8. Check the transmission fluid level. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 10855 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 10856 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 10857 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission Fluid Line/Hose: Service and Repair Allison - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Pull the plastic cap back from the quick connect fitting. 3. Remove the cooling lines from the clips. 4. Remove the two retaining rings securing the two cooling lines to the transmission. 5. Use a bent tip screwdriver. 6. Pull on the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of the fitting. Discard the retaining ring. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10860 7. Pull the cooling line straight out from the quick connect fitting. 8. Repeat this procedure to remove all the remaining cooling lines from quick connect fittings. 9. For vehicles without an auxiliary cooler, remove the cooling lines from the radiator. 10. For vehicles with auxiliary cooling, remove the cooling lines from the radiator. 11. Remove the oil cooling lines from the auxiliary oil cooler. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install a NEW retaining ring (E-clip) into the quick connect fitting using the following procedure: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10861 Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 7. Install the NEW retaining ring (E-clip) into the remaining quick connect fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10862 8. Install the cooler line into the quick connect fitting. 9. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 10. Install the cooler lines to the vehicle. 11. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 12. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 13. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 14. Ensure that the plastic cap is fully seated against the fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10863 15. Ensure that no gap is present between the cap and the fitting. 16. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 17. Do not install the cooler line end into the fitting incorrectly. 18. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall the cooler line per the installation procedure. 19. For vehicles without auxiliary cooling, install the cooling lines to the radiator. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10864 20. For vehicles with auxiliary cooling, install the cooling lines to the radiator. 21. For vehicles with auxiliary cooling, install the oil cooling lines to the auxiliary oil cooler. 22. Install the cooling lines to the transmission. 23. Install the cooling lines to the clips. 24. Ensure all of the protective plastic caps are positioned over all of the quick connect fittings. 25. Lower the vehicle. 26. Check and add fluid as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10865 Fluid Line/Hose: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grille. 2. Disconnect the auxiliary transmission fluid cooler lines from the auxiliary oil cooler. 3. Disconnect the transmission fluid cooler lines from the radiator. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the engine protection shield. 6. Disconnect the oil cooler lines from the transmission. 7. Remove the oil cooler lines from the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10866 Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Connect the cooling lines to the transmission. 3. Install the engine protection shield. 4. Lower the vehicle. 5. Connect the transmission fluid cooler lines from the radiator. 6. Connect the transmission fluid cooler hose to the Auxiliary oil cooler. 7. Install the front grille. Transmission Fluid Cooler Line Quick Connect Fitting Transmission Fluid Cooler Line Quick Connect Fitting Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10867 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Install a new retaining ring into the quick connect fitting using the following procedure: Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10868 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10869 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10870 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10871 Fluid Line/Hose: Service and Repair 4L80-E/4L85-E - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the engine protection shield. 6. Remove the transmission fluid cooler hoses from the transmission. 7. Remove the transmission fluid cooler hoses from the retainer on the engine. 8. Remove the transmission fluid cooler hoses from the vehicle. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10872 1. Install the transmission fluid cooler hoses to the vehicle. 2. Install the transmission fluid cooler hoses to the transmission. 3. Install the transmission fluid cooler hoses to the retainer on the engine. 4. Install the engine protection shield. 5. Lower the vehicle. 6. Install the transmission fluid cooler hose to the radiator. 7. Install the transmission fluid cooler hose from the Auxiliary oil cooler. 8. Install the grille assembly. Transmission Fluid Cooler Line Quick Connect Fitting Transmission Fluid Cooler Line Quick Connect Fitting Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10873 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Install a new retaining ring into the quick connect fitting using the following procedure: Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10874 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10875 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Allison - Automatic Transmission > Page 10876 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Vent Hose Vent Hose Removal Procedure 1. Remove the vent hose clip. 2. Remove the vent hose from the transmission vent. Installation Procedure 1. Install the vent hose to the transmission. 2. Install the vent hose to the clip. 3. Install the bolt and the clamp. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 10881 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 10882 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pan: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission (M30/M32 Only) Oil Pan to Transmission Case Bolt ........................................................................................................................................................ 11 Nm (97 inch lbs.) (M33 Only) Oil Pan to Transmission Case Bolt ........................................................................................................................................................ 16 Nm (11.8 ft. lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10885 Fluid Pan: Specifications 4L80-E/4L85-E - Automatic Transmission Oil Pan Drain Plug ............................................................................................................................... ..................................................... 34 Nm (25 ft. lbs.) Oil Pan to Case ................................................ ......................................................................................................................................... 24 Nm (18 ft. lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10886 Fluid Pan: Specifications Allison - Automatic Transmission Oil Pan to Main Housing Bolts ............................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Oil Pan Drain Plug ........................................... .......................................................................................................................................... 35 Nm (26 ft. lbs.) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 10887 Fluid Pan: Application and ID Fluid Pan Identification 1 - Deep Sump 2 - Hybrid Pickup Truck - M33 Model 3 - Colorado/Canyon - GMT 345/355 4WD 4 Pan Magnet Location Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 10888 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the drain plug (7) and drain plug seal (6) from the oil pan (5). Allow the fluid to drain into a suitable container. Important: It would be helpful to record the amount of transmission fluid lost during this procedure. Fluid in good condition, drained into a clean container, may be reused. 3. Inspect the drained fluid. 4. Remove 12 bolts (8). Hold the oil pan in position as the last bolt is removed. 5. Remove oil pan (5) and gasket (3). 6. Inspect magnet (4). Excessive metallic particles or large metallic particles may indicate need for overhaul or replacement of the transmission. 7. Remove the transmission internal oil filter (2) by pulling straight down where the suction tube is seated in the transmission case. Important: DO NOT remove the transmission internal oil filter or seal if only replacing the oil pan or oil pan gasket. 8. Remove the transmission internal oil filter seal (1) from the filter or from the seal bore in the transmission case. Discard the old seal. Discard the filter, if the filter is being replaced. Installation Procedure 1. Remove all gasket material from the transmission case. Remove any scratches from the transmission case that would cause a splitline leak. 2. Place a new seal (1) on the tube of the transmission internal oil filter (2), if the filter was removed. Be sure the seal locates against the shoulder on the internal oil filter tube. 3. Push the filter (2) and seal (1) into the seal bore in the transmission case. Position the transmission internal oil filter properly. 4. Install 2 headless guide bolts (9), M8 x 1.25, into opposite corners of the oil pan mounting face on the transmission case. 5. Place a gasket (3) on the oil pan and align the bolt holes. 6. Slide the gasket (3) and oil pan (5) over the guide bolts and hold them in place while installing 2 bolts (8) to hold the parts in place. 7. Remove the guide bolts. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 10889 8. Install the 10 remaining oil pan bolts (8). ^ Tighten the bolts to 27 Nm (20 ft. lbs.). 9. Install the drain plug (7) and drain plug seal (6). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). Notice: Refer to Component Fastener Tightening Notice in Service Precautions. 10. Lower the vehicle. 11. Refill the transmission with DEXRON(r)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Notice: Use only clean and approved transmission fluid. 12. Check the transmission fluid level. Important: Remember fluid remains in the external circuits and transmission cavities after draining the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10894 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10897 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10898 Fluid Pressure Sensor/Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10901 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10902 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Remove the remaining valve body bolts. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10903 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10904 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10905 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10906 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10907 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10908 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10909 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10910 Fluid Pressure Sensor/Switch: Service and Repair 4L80-E/4L85-E - Automatic Transmission Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel(r) Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body: ^ The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10911 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10912 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Remove the 8 checkballs (9 for some models). Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10913 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Install the manual 2-1 band servo piston (1). Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10914 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10915 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10916 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10917 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Fluid Pump: Customer Interest A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 10926 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 10927 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 10928 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Fluid Pump: All Technical Service Bulletins A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 10934 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 10935 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 10936 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 10937 Secondary Fluid Pump Assembly Specifications (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 10938 Fluid Pump: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 10939 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 10940 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 10941 Fluid Pump: Diagrams Automatic Transmission Internal Connector End Views (M33 Only) Auxiliary Transmission Fluid Pump (M33 Only) Auxiliary Transmission Fluid Pump (M33 Only) Auxiliary Transmission Fluid Pump (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The instrument panel cluster (IPC) displays the selected gear position as determined by the powertrain control module (PCM). The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Yoke, A/T > Component Information > Service and Repair Output Yoke: Service and Repair Output Flange/Yoke Replacement Removal Procedure 1. Place the transmission in the Park (P) selector position. 2. Apply the parking brake and chock the wheels to prevent vehicle movement. Caution: Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury. 3. Remove the vehicle driveline from the transmission yoke assembly (1). Remove the bolt (3) and seal ring washer (2). Remove the yoke assembly (1). 4. Inspect the yoke assembly and replace it whenever there are nicks or scratches on the seal journal or on the lead-in chamfer just ahead of the seal journal. Important: Do the following prior to installation of the yoke assembly: ^ Be sure the yoke, output shaft and retaining hardware are clean. ^ Verify the output seal is free of tears or cuts. ^ DO NOT attempt to remove scratches from the output seal journal on the yoke assembly. Repair may produce machine lead and leakage. Installation Procedure 1. Lubricate the internal splines and the rear seal journal of the yoke assembly with clean transmission fluid. 2. Install the yoke assembly (1) onto the transmission output shaft. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt (3) and seal ring washer (2). ^ Tighten the bolt to 123 Nm (91 ft. lbs.). 4. Attach the vehicle driveline to the transmission yoke assembly. 5. Be sure the selector is in the Park (P) position. 6. Remove the wheel chocks before continuing operation of the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission Parking Pawl: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Remove the manual shaft. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission > Page 10957 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite(r) or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission > Page 10958 Parking Pawl: Service and Repair Allison - Automatic Transmission Manual Detent Spring and Roller Replacement Manual Detent Spring and Roller Replacement Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Remove the 2 detent spring bolts (3). Remove the detent spring assembly (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission > Page 10959 1. Install the detent spring assembly (2) onto the control valve assembly. Confirm that the roller of the detent spring assembly rests on the detent lever (1). 2. Install 2 detent spring bolts (3). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pan and transmission internal oil filter. Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 Torx(r) bit and discard the retaining bolt. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission > Page 10960 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). 2. Push the manual shift shaft (5) into the final position in the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 Torx(r) bit. ^ Tighten the bolt (1) to 10 Nm (92 inch lbs.). 5. Install the control valve assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10965 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10968 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Control Solenoid 2 (PCS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10969 Pressure Switch Manifold (PSM) Pressure Switch Manifold (PSM) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10970 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10971 Pressure Control (PC) Solenoid Valve, Wiring Harness Side Pressure Control (PC) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Allison - Automatic Transmission > Page 10972 Pressure Regulating Solenoid: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid Valve, Wiring Harness Side Pressure Control Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulating Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10975 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10976 Pressure Regulating Solenoid: Service and Repair 4L80-E/4L85-E - Automatic Transmission Pressure Regulator Replacement ^ Tools Required J 36850 Transjel(r) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the transmission filter. 3. Remove the reverse boost valve bushing retainer ring (2). Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 10977 2. Pre-assemble the following parts: ^The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10983 Control Module: Diagrams Automatic Transmission Related Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10984 Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10985 Transmission Control Module (TCM) 80-Way Connector Transmission Control Module (TCM) 80-Way Connector Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10986 Control Module: Service and Repair Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module (TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10987 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Connect the negative battery cable. 6. Reprogram the TCM. Refer to Control Module References in Computer/Integrating Systems. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 10996 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Seals and Gaskets: Customer Interest A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11001 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11002 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11003 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 11009 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11014 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11015 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11016 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11017 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11018 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-07-30-016 Date: 060718 A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11019 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11020 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11021 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11022 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-07-30-016 Date: 060718 A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11023 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11024 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 11025 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission Seals and Gaskets: Service and Repair Allison - Automatic Transmission Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. The transmission case has provisions that enable the fill tube to be installed on either the right or left side of the transmission. Proceed to step 9 if servicing the plug and/or seal opposite the fill tube. 2. If the vehicle is equipped with a diesel engine, the transmission must be removed to service the fill tube and/or seal. 3. Remove the transmission fluid level indicator. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the fill tube nuts. 6. Place a drain pan under the transmission to catch any dripping fluid. 7. Loosen the fill tube from the transmission. 8. Remove the fill tube and seal from the vehicle. 9. Remove the fill tube plug (1). 10. Remove the fill tube plug seal (2). Installation Procedure 1. Install a new fill tube plug seal (2) into the main housing. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11028 2. Align the tab on the fill tube plug (1) with the tang on the main housing. 3. Install the fill tube plug (1). Press the plug into the seal (2) until the tab on the fill tube plug locks into place in the notch on the main housing. 4. Install a NEW fill tube seal. 5. Install the fill tube. Ensure that the fill tube bracket is positioned properly on the studs. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the fill tube nuts. ^ Tighten the nuts to 18 Nm (13 ft. lbs.). 7. Lower the vehicle. 8. Fill the transmission to the proper level with approved fluid. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Manual Shift Shaft Seal Remover - J 43909 Manual Shift Shaft Seal Installer Removal Procedure 1. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the manual shift shaft (2) with the threaded end of the tool towards the seal. 2. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 3. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11029 1. Carefully slide a new manual shift shaft seal (1) over the manual shift shaft (2) with the wide face of the steel case facing outward. Position so that the seal is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the manual shift shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until the seal is seated at the bottom of the bore. PTO Cover Gasket Replacement PTO Cover Gasket Replacement Removal Procedure 1. Remove 6 bolts (3). 2. Remove the power take-off (PTO) cover (2) and gasket (1). Discard the used gasket. 3. Ensure the PTO gasket face on the transmission case is free of all foreign material, nicks and scratches. Installation Procedure 1. Install the new PTO cover gasket (1) and cover (2). 2. Start the top-center bolt (3) first. Install the other 5 bolts. ^ Tighten all bolts to 43 Nm (32 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11030 Notice: Refer to Fastener Notice in Service Precautions. Seal Replacement - Rear Propshaft Seal Replacement - Rear Propshaft ^ Tools Required J 24171-A Seal and Dust Shield Remover - J 43782 Rear Seal Installer Removal Procedure 1. Remove the yoke assembly from the transmission. 2. Obtain J 24171-A and install a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal's outer case (2). 4. Remove the rear seal using the slide-hammer. 5. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure 1. Align the seal so the seal lip (2) is outward and the face of the steel case (1) will be against the driving face (3) of the tool. Install the new seal onto J 43782. Important: Be sure the new seal has blue sealant coating the OD (4). This identifies the seal for use in the 1000 Series transmissions. The blue sealant identification is important because the 1000 Series transmissions have an overdrive ratio in fifth range and there is a potential for high output shaft speeds and resultant high seal temperature. 2. Slide J 43782 over the output shaft until the seal enters the seal bore. Strike J 43782 with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of J 43782 squarely contacts the outer surface of the rear cover. 3. Install the yoke assembly onto the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11031 Seal Replacement - Torque Converter Seal Replacement - Torque Converter ^ Tools Required J 24171-A Seal and Dust Shield Remover - J 43772 Torque Converter Seal Installer Removal Procedure 1. Remove the torque converter from the transmission. 2. Obtain J 24171-A and install the tip (3) with a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal outer case (2). Remove the torque converter seal using the slide-hammer. 4. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure 1. Install the new seal (2) onto the J 43772. Position the seal so the seal lip is outward and the face of the steel case is against the driving face (1) on the tool. 2. Slide J 43772 over the turbine shaft and the stator shaft until the seal starts into the seal bore. Strike the J 43772 with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of the J 43772 squarely contacts the outer surface of the oil pump. 3. Install the torque converter into the transmission. Torque Converter Housing Bolt Seal Replacement Torque Converter Housing Bolt Seal Replacement Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11032 1. Remove the torque converter from the transmission. 2. Remove any of the 10 bolts (1), bolt heads shaded, where leakage at the bolt head is suspected. 3. Remove and discard seals from bolts removed. Important: Bolts (1) have a removable seal under the flanged head. Installation Procedure 1. Install new seals on any bolts (1) removed. 2. Install any bolts (1) removed. ^ Tighten bolts to 56 Nm (41 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the torque converter into the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11033 Seals and Gaskets: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Unlock the transmission oil level indicator. 2. Remove the transmission oil level indicator. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Support the transmission using a suitable jack. 5. Remove the transmission mount nut. 6. Remove the transmission crossmember bolts/nuts. 7. Remove the transmission crossmember. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11034 8. Loosen the left exhaust pipe nuts. 9. Loosen the right exhaust pipe nuts. 10. Remove the insulator nuts and insulator from the bracket. 11. Remove the exhaust pipe hanger bracket bolts and bracket. 12. Lower the transmission slightly. 13. Disconnect the transmission oil cooler lines. 14. Plug the transmission oil cooler line fittings. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11035 15. Remove the indicator tube nut. 16. Remove the indicator tube bolt, if equipped with RPO HP2. 17. Remove the oil level indicator tube. 18. Remove the seal from the transmission, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11036 19. Remove the oil level indicator tube, if equipped with RPO HP2. 20. Remove the seal from the transmission, if necessary. Installation Procedure 1. Install a NEW seal to the indicator tube. 2. Install the oil level indicator tube, if equipped with RPO HP2. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11037 3. Install a NEW seal to the indicator tube. 4. Install the oil level indicator tube. 5. Install the indicator tube bolt, if equipped with RPO HP2. ^ Tighten the bolt to 18 Nm (13 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the indicator tube nut. ^ Tighten the nut to 18 Nm (13 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11038 7. Remove the plugs from the transmission oil cooler line fittings. 8. Connect the transmission oil cooler lines. 9. Install the exhaust pipe hanger bracket and bolts. ^ Tighten the bolts to 17 Nm (12 ft. lbs.). 10. Instal the insulator and nuts to the bracket. ^ Tighten the nuts to 17 Nm (12 ft. lbs.). 11. Tighten the right exhaust pipe nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). 12. Tighten the left exhaust pipe nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11039 13. Install the transmission crossmember. 14. Install the transmission crossmember bolts/nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 15. Install the transmission mount nut. ^ Tighten the nut to 50 Nm (37 ft. lbs.). 16. Remove the support from the transmission. 17. Lower the vehicle. 18. Install the transmission oil level indicator. 19. Lock the transmission oil level indicator. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11040 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Accumulator Assembly, Spacer Plate, and Gaskets Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11041 1. Remove the transmission filter. 2. Remove the valve body. Important: The 1-2 accumulator can be removed without removing the valve body. 3. Remove the accumulator cover bolts. 4. Remove the 1-2 accumulator cover. 5. Remove the 1-2 accumulator cover (57) and pin. Important: Regular production option (RPO) M33 transmissions do not use a 1-2 accumulator spring inner (104). 6. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104). 7. Inspect the 1-2 accumulator springs for cracks. 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following conditions: ^ Porosity ^ Cracks Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11042 ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support bolts. 12. Remove the spacer plate support. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11043 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11044 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11045 10. Install the spacer plate support and the spacer plate support bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11046 13. Assemble the 1-2 accumulator assembly (54, 56, 57, 104). Ensure that the piston legs face the accumulator cover. Important: RPO M33 transmissions do not use a 1-2 accumulator spring inner (104). 14. Install the 1-2 accumulator cover (57) and pin. 15. Install the 1-2 accumulator cover and the accumulator cover bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the valve body. 18. Install the transmission filter. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transjel Lubricant Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11047 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11048 Seals and Gaskets: Service and Repair 4L80-E/4L85-E - Automatic Transmission Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Remove the oil level indicator. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the fill tube bracket nut. 4. Place a drain pan under the transmission. 5. Remove the fill tube. 6. Remove the transmission fill tube seal. Installation Procedure 1. Install the transmission fill tube seal. 2. Install the fill tube. 3. Remove the drain pan from under the transmission. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11049 4. Install the fill tube bracket nut. 5. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil level indicator. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 7. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the J 43911 so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11050 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Using J 43909, remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON(r) III transmission fluid. Transmission Extension Housing Assembly Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 41505 Output Shaft Seal Installer - J 6125-1BSlide Hammer - J 23129 Universal Seal Remover - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Using the J 6125-1B (1) and the J 23129 (2), remove the output shaft seal (3) from the extension housing (4). 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Allison - Automatic Transmission > Page 11051 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 41505 (1) with a soft faced mallet to install the seal (2). 3. Install the seal (2) to the extension housing (3). 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with Dexron(r) III transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11057 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11060 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11061 Fluid Pressure Sensor/Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Automatic Transmission Fluid Pressure Manual Valve Position Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11064 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11065 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Remove the remaining valve body bolts. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11066 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11067 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11068 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11069 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11070 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11071 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11072 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11073 Fluid Pressure Sensor/Switch: Service and Repair 4L80-E/4L85-E - Automatic Transmission Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel(r) Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body: ^ The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11074 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11075 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Remove the 8 checkballs (9 for some models). Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11076 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Install the manual 2-1 band servo piston (1). Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11077 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11078 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11079 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11080 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Tow/Haul Switch: Locations Automatic Transmission Electronic Component Views Transmission Control Module (MW7) Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Engine Harness to Transmission Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 11084 Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Tow/Haul Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11087 Tow/Haul Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11088 Tow/Haul Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Transmission Internal Mode Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > Page 11089 Tow/Haul Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 11093 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 11094 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11097 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11100 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11103 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11104 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11105 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11106 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11107 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11108 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11113 Transmission Speed Sensor: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Vehicle Speed Sensor Assembly, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11116 Transmission Speed Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11117 Automatic Transmission Output Speed Sensor (OSS) Automatic Transmission Output Speed Sensor (OSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11118 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11119 Automatic Transmission Turbine Speed Sensor Automatic Transmission Turbine Speed Sensor Vehicle Speed Sensor (VSS) Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11122 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11123 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11124 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11125 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11126 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11127 Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure 1. Be sure the vehicle ignition is turned off. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11128 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Install the speed sensor bolt (1). ^ Tighten bolt to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11133 Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11134 Transmission Temperature Sensor/Switch: Specifications Allison - Automatic Transmission Temperature vs Resistance (Transmission Fluid Temperature Sensor) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 11135 Temperature vs Resistance (Speed Sensor) Temperature vs Resistance (Solenoid) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 11136 Transmission Temperature Sensor/Switch: Locations Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 11137 Transmission Temperature Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Transmission Fluid Temperature (TFT) Sensor, Wiring Harness Side Transmission Fluid Temperature (TFT) Sensor, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Caution: Refer to SIR Caution in Service Precautions. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 11142 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State And Gear Ratio 4L60-E/4L70-E Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11147 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11150 Shift Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 Shift Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11170 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11171 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11172 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11173 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11174 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11175 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11176 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11177 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11178 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11179 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11180 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11181 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11182 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11183 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11184 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11185 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11186 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11187 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11188 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11189 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11190 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11191 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11192 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11193 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11194 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11195 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11196 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11197 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11198 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11199 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11200 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11201 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11202 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11203 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11204 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11205 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11206 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11207 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11208 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11209 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11210 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11211 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11212 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11213 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11214 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11215 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11216 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11217 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11218 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11219 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11220 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11221 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11222 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11223 Shift Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11224 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11225 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11226 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11227 3-2 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11228 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11229 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 2-3 Shift Solenoid (SS), Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11230 Shift Solenoid 1 (SS1) Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Shift Solenoid 2 (SS2) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11231 Shift Solenoid 3 (SS3) Shift Solenoid 3 (SS3) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11232 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11235 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11236 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11237 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11238 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11239 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11240 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11241 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11242 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair Shift Lever Replacement (With Tow/Haul Switch) Removal Procedure 1. Remove the trim covers. 2. Roll back the seal on the shift lever (1) until the TORX head shift lever screw (2) is exposed. 3. Remove the TORX head shift lever screw (2). 4. Remove the knee bolster. 5. Remove the nuts (1) from the knee bolster deflector bracket. 6. Remove the wiring harness retaining pin (4) from the instrument panel. Notice: During removal of the steering column the wire harness retaining clip must be removed and reinstalled after installing the steering column or damage may occur to the wire harness. 7. Remove the wire straps and open the harness insulation to gain access to the electrical wiring. 8. Remove the wiring from the electrical connector. 9. Remove the shift lever. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Page 11246 1. Install the shift lever (1). 2. Connect the shifter electrical connector. 3. Install the wire straps to the harness. 4. Install the harness retaining pin (4) to the instrument panel. 5. Install the knee bolster deflector bracket and nuts (1). ^ Tighten the nuts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console. 7. Install the TORX head shift lever screw. ^ Tighten the screw to 20 Nm (15 ft. lbs.). 8. Roll the seal over the TORX head shift lever screw. 9. Install the 2 TORX head screws to the lower column trim cover. 10. Install the trim covers. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission Shift Cable: Adjustments Allison - Automatic Transmission Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11252 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11253 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11254 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11255 Shift Cable: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11256 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11257 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11258 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11259 Shift Cable: Adjustments 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11260 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11261 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Allison - Automatic Transmission > Page 11262 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Cable: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. 3. Remove the driver's seat. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11265 9. Remove the range selector cable from the support. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11266 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11267 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Install the range selector cable to the support. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 10. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 11. Install the cable to the steering column bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11268 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. 17. Install the instrument panel knee bolster. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Refer to Automatic Transmission Range Selector Cable Adjustment. Automatic Transmission Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Remove the retainer that secures the cable to the bracket. 5. Depress the tangs and remove the cable from the bracket. 6. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 7. Remove the transmission range selector cable bracket. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11269 1. Install the transmission range selector cable bracket. 2. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. 5. Lower the vehicle. 6. Check the vehicle for proper operation. If cable adjustment is necessary, refer to Automatic Transmission Range Selector Cable Adjustment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11270 Shift Cable: Service and Repair 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. 3. Remove the driver's seat. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11271 9. Remove the range selector cable from the support. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11272 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11273 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Install the range selector cable to the support. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 10. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 11. Install the cable to the steering column bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11274 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. 17. Install the instrument panel knee bolster. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Automatic Transmission Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11275 2. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. If adjustment of the cable is necessary, Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11276 Shift Cable: Service and Repair Allison - Automatic Transmission Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the shift lever into the park (P) position. 2. Remove the instrument panel knee bolster. 3. Remove the retainer securing the cable to the steering column. 4. Remove the cable end from the steering column ball stud. 5. Depress the tangs and remove the cable from the steering column bracket. 6. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11277 7. Remove the range selector cable from the support. Important: Avoid unnecessary twisting/bending of the selector cable when removing the cable from the support. 8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 9. Ensure the transmission manual shaft is positioned in mechanical park. 10. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 11. Remove the retainer securing the cable to the bracket. 12. Depress the tangs and remove the cable from the transmission bracket. 13. Remove the cable clips from the floor panel reinforcement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11278 14. Remove the cable clips (2) from the transfer case, if equipped. 15. Lower the vehicle. 16. Pull back the carpet and insulation around the driver's area. 17. Remove the cable grommet from the floor panel. 18. Remove the cable from the hole in the floor panel. Installation Procedure 1. Instal the cable to the hole in the floor panel. 2. Install the cable grommet to the floor panel. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11279 3. Position the carpet and insulation around the driver's area. 4. Raise the vehicle. 5. Install the cable clips (2) to the transfer case, if equipped. 6. Install the cable clips to the floor panel reinforcement. 7. Ensure the transmission manual shaft is positioned in mechanical park. 8. Install the cable to the transmission bracket. 9. Install the retainer securing the cable to the bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11280 10. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 11. Lower the vehicle. 12. Install the range selector cable to the support. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 13. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 14. Install the cable to the steering column bracket. 15. Install the cable end to the steering column ball stud. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11281 16. Install the retainer securing the cable to the steering column. 17. Install the instrument panel knee bolster. 18. If all of the gear positions cannot be achieved, adjust the cable. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Torque Converter: Customer Interest A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Bulletin No.: 06-07-30-017A Date: August 16, 2006 TECHNICAL Subject: 4L60-E, 4L65-E, 4L70-E Automatic Transmission High Pitched Whine, Whistle, Chirp or Buzz Type Noise at 1,500-1,800 RPM (Replace with Updated Torque Converter) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Chevrolet Corvette 2005-2006 Chevrolet Silverado, Silverado SS, SSR 2006 Chevrolet TrailBlazer SS 2005-2006 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2005-2006 Pontiac GTO 2005-2006 HUMMER H2, H2 SUT with 4L65-E, 4L70-E Automatic Transmission (RPOs M32 or M70) 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL with 4L60-E Automatic Transmission (RPO M30) Supercede: This bulletin is being revised to update Transmission RPO usage information in the Parts table. Please discard Corporate Bulletin Number 06-07-30-017 (Section 07 - Automatic Transmission). Condition Some customers may comment on a high pitched whistle or whine type noise at approximately 1,500-1,800 rpm while in any forward gear with the torque converter clutch (TCC) disengaged. This noise is typically easier to duplicate when driving up a slight grade when accelerating. This noise will stop when the TCC is engaged. Some 2007 vehicles have been reported to exhibit this noise in 1st gear at approximately 16 km/h (10 mph) with 30-50% TPS on a launch from a stop. Cause The torque converter pump blade may cause this condition. A torque converter pump blade revision is expected in production by the end of July, 2006. Correction To determine the location of the noise, use the chassis ears with a small acoustic clip-on microphone (such as Radio Shack P/N 33-3013) plugged into the chassis ear amplifier. Drive the vehicle to duplicate the concern using the chassis ears and the Tech 2 to apply and release the TCC. If the noise is coming from the bell housing area only, when the TCC is commanded off, replace the torque converter. If the noise is present with the TCC commanded on, this noise is not caused by the torque converter and torque converter replacement will not correct the condition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 11290 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 11291 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 11292 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Torque Converter: Customer Interest A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11297 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11298 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11299 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information > Page 11305 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Torque Converter: All Technical Service Bulletins A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Bulletin No.: 06-07-30-017A Date: August 16, 2006 TECHNICAL Subject: 4L60-E, 4L65-E, 4L70-E Automatic Transmission High Pitched Whine, Whistle, Chirp or Buzz Type Noise at 1,500-1,800 RPM (Replace with Updated Torque Converter) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Chevrolet Corvette 2005-2006 Chevrolet Silverado, Silverado SS, SSR 2006 Chevrolet TrailBlazer SS 2005-2006 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2005-2006 Pontiac GTO 2005-2006 HUMMER H2, H2 SUT with 4L65-E, 4L70-E Automatic Transmission (RPOs M32 or M70) 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL with 4L60-E Automatic Transmission (RPO M30) Supercede: This bulletin is being revised to update Transmission RPO usage information in the Parts table. Please discard Corporate Bulletin Number 06-07-30-017 (Section 07 - Automatic Transmission). Condition Some customers may comment on a high pitched whistle or whine type noise at approximately 1,500-1,800 rpm while in any forward gear with the torque converter clutch (TCC) disengaged. This noise is typically easier to duplicate when driving up a slight grade when accelerating. This noise will stop when the TCC is engaged. Some 2007 vehicles have been reported to exhibit this noise in 1st gear at approximately 16 km/h (10 mph) with 30-50% TPS on a launch from a stop. Cause The torque converter pump blade may cause this condition. A torque converter pump blade revision is expected in production by the end of July, 2006. Correction To determine the location of the noise, use the chassis ears with a small acoustic clip-on microphone (such as Radio Shack P/N 33-3013) plugged into the chassis ear amplifier. Drive the vehicle to duplicate the concern using the chassis ears and the Tech 2 to apply and release the TCC. If the noise is coming from the bell housing area only, when the TCC is commanded off, replace the torque converter. If the noise is present with the TCC commanded on, this noise is not caused by the torque converter and torque converter replacement will not correct the condition. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 11310 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 11311 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 11312 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Torque Converter: All Technical Service Bulletins A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area Bulletin No.: 06-07-30-016 Date: July 18, 2006 TECHNICAL Subject: 4L60-E, 4L65-E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Remove Small Burrs On Torque Converter Hub, Pump Drive Slots and Replace Torque Converter Hub-to-Oil Pump Seal Assembly (243)) Models: 2006 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet Colorado, Corvette, Express, Silverado, SSR, TrailBlazer 2006-2007 Chevrolet Avalanche, Suburban, Tahoe 2006 GMC Canyon, Envoy, Savana, Sierra 2006-2007 GMC Yukon 2007 GMC Yukon XL 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission (RPOs M30 or M32) Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. This leak may be very slight with only dampness of one or two drops of ATF observed at the bottom of the bellhousing. Cause Investigation of 2006 transmissions has shown small scratches or cuts in the torque converter hub-to-pump seal (243). These scratches or cuts may be caused by small burrs on the torque converter hub, pump drive slots. Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If this is a vehicle with very low mileage and it appears to have a small leak, it could have assembly oil in the bell housing which is not truly a leak. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11317 Once the dye has started to appear, disassemble and inspect for small cuts in the torque converter hub-to-oil pump seal assembly (243). The cuts may be caused by small burrs on the torque converter hub, oil pump drive slots. The burrs can be seen or felt with your finger and if found, the burrs should be removed with a file. Also replace the oil pump seal assembly. Refer to the above illustration (1).Do not replace the torque converter for this concern. The torque converter hub-to-oil pump seal assembly leak caused by these cuts is typically very small, causing only a few drops of fluid loss. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11318 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-016 > Jul > 06 > A/T - 4L60-E, 4L65-E Fluid Leak From Bell Housing Area > Page 11319 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information > Page 11325 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 11326 Torque Converter: Application and ID Torque Converter Housing Identification 1 - Domestic Gen III Large Bell V-8 (300 mm) 2 - Domestic Small Bell V-6 3 - Domestic Bell L-6 4 Hybrid Pickup Truck - V8 Bell 5 - HF V6 Bell - Domestic/Holden Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 11327 Torque Converter: Service and Repair Torque Converter Replacement ^ Tools Required J 21366 Converter Holding Strap - J 46409 Torque Converter Lifting Handles - J 44723 Transmission/Stand Adaptor Plate Removal Procedure 1. Remove the transmission from the vehicle. 2. Install J 21366 to restrain the torque converter. 3. Install J 44723. 4. Position the transmission vertically with the torque converter end up. 5. Remove J 21366 torque converter retaining bracket. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 11328 6. Measure from the mounting lugs to the transmission mounting face. Important: The distance from the torque converter mounting lugs to the transmission mounting face is an important measurement. It is required to check correct reassembly of the torque converter. 7. Install J 46409 180 degrees apart into 2 lugs on the front of the torque converter. 8. Lift the torque converter free of the transmission and place it on the work table. Caution: Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. 9. Remove the lifting handles. Installation Procedure 1. Lubricate the converter pump hub OD and the torque converter seal with clean transmission fluid. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 11329 2. Install J 46409 180 degrees apart into 2 lugs on the front of the torque converter. 3. Lift the torque converter into the transmission. Caution: Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. 4. Spin the torque converter to engage the turbine shaft splines in the torque converter hub, the stator shaft splines in the stator race and to engage the drive flats on the converter pump hub with the oil pump drive gear. 5. The torque converter is correctly installed when the distance from the lugs to the mounting face is the same as when measured before removing the torque converter. 6. Install J 21366. 7. Reinstall the transmission into the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 11334 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > Page 11335 Torque Converter Check Valve: Service and Repair Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Remove the transmission filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 2. Remove the valve bore plug retainer ring (1). 3. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > Page 11336 2. Install the valve bore plug retainer ring (1). 3. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 06-07-30-007A > Feb > 07 > A/T - MIL ON/DTC P0894/Harsh 1-2 Shift Torque Converter Clutch: Customer Interest A/T - MIL ON/DTC P0894/Harsh 1-2 Shift Bulletin No.: 06-07-30-007A Date: February 20, 2007 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Diagnostic Trouble Code (DTC) P0894, Harsh 1-2 Shift with 4L60-E, 4L65-E, 4L70-E Automatic Transmission (Test and Replace Torque Converter Clutch (TCC) Enable Solenoid/Harness, Auto Trans Wiring) Models: 2006 Cadillac Escalade Models 2006 Chevrolet Light Duty Trucks 2006 Chevrolet Express Vans 2006 GMC Light Duty Trucks 2006 GMC Savana Vans 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E / 4L65-E / 4L70-E (RPOs M30, M32, M70) Automatic Transmission Supercede: This bulletin is being revised to add part number for vehicles with Input Speed Sensor (ISS). Please discard Corporate Bulletin Number 06-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a harsh 1-2 shift with the MIL illuminated. Diagnosis with a scan tool may reveal a DTC P0894. Cause This condition may be caused by a leaking TCC enable solenoid. The TCC enable solenoid is part of the automatic transmission wiring harness. Correction Follow the diagnosis and repair procedure below for a DTC P0894. With a scan tool, verify the presence of DTC P0894. Remove the TCC Enable solenoid / automatic transmission wiring harness. Refer to Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness in the appropriate SI Document. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 06-07-30-007A > Feb > 07 > A/T - MIL ON/DTC P0894/Harsh 1-2 Shift > Page 11345 Typically if the TCC enable solenoid is found to have a crack/fracture (2), it will be located parallel to the mold seam (1) as shown above. Engineering investigation shows that TCC enable solenoids that are brown in color may exhibit the cracking / fracture condition. Engineering investigation shows that TCC enable solenoids that are off-white in color do not exhibit the cracking / fracture condition. Air check the TCC enable solenoid using J 44246 solenoid testing kit. Install the TCC enable solenoid into bore # 2 of J 44246 as shown above. While air is being applied to the solenoid through J 44246, coat the outside of the solenoid body with transmission fluid to help expose a possible vertical crack in the molded part of the solenoid body. This crack may be very small and not visible without the use of ATF. Complete instructions for the Shift Solenoid Leak Test can be found in SI Document ID # 856531. If NO visual leaks are found in the TCC enable solenoid, refer to DTC P0894 in the appropriate SI Document. If visual leaks are found in the TCC enable solenoid, continue with the next step. Replace the TCC enable solenoid. Refer to Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness in the appropriate SI Document. Road test the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 06-07-30-007A > Feb > 07 > A/T - MIL ON/DTC P0894/Harsh 1-2 Shift > Page 11346 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 06-07-30-007A > Feb > 07 > A/T - MIL ON/DTC P0894/Harsh 1-2 Shift Torque Converter Clutch: All Technical Service Bulletins A/T - MIL ON/DTC P0894/Harsh 1-2 Shift Bulletin No.: 06-07-30-007A Date: February 20, 2007 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Diagnostic Trouble Code (DTC) P0894, Harsh 1-2 Shift with 4L60-E, 4L65-E, 4L70-E Automatic Transmission (Test and Replace Torque Converter Clutch (TCC) Enable Solenoid/Harness, Auto Trans Wiring) Models: 2006 Cadillac Escalade Models 2006 Chevrolet Light Duty Trucks 2006 Chevrolet Express Vans 2006 GMC Light Duty Trucks 2006 GMC Savana Vans 2006 Pontiac GTO 2006 HUMMER H2, H3 2006 Saab 9-7X with 4L60-E / 4L65-E / 4L70-E (RPOs M30, M32, M70) Automatic Transmission Supercede: This bulletin is being revised to add part number for vehicles with Input Speed Sensor (ISS). Please discard Corporate Bulletin Number 06-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a harsh 1-2 shift with the MIL illuminated. Diagnosis with a scan tool may reveal a DTC P0894. Cause This condition may be caused by a leaking TCC enable solenoid. The TCC enable solenoid is part of the automatic transmission wiring harness. Correction Follow the diagnosis and repair procedure below for a DTC P0894. With a scan tool, verify the presence of DTC P0894. Remove the TCC Enable solenoid / automatic transmission wiring harness. Refer to Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness in the appropriate SI Document. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 06-07-30-007A > Feb > 07 > A/T - MIL ON/DTC P0894/Harsh 1-2 Shift > Page 11352 Typically if the TCC enable solenoid is found to have a crack/fracture (2), it will be located parallel to the mold seam (1) as shown above. Engineering investigation shows that TCC enable solenoids that are brown in color may exhibit the cracking / fracture condition. Engineering investigation shows that TCC enable solenoids that are off-white in color do not exhibit the cracking / fracture condition. Air check the TCC enable solenoid using J 44246 solenoid testing kit. Install the TCC enable solenoid into bore # 2 of J 44246 as shown above. While air is being applied to the solenoid through J 44246, coat the outside of the solenoid body with transmission fluid to help expose a possible vertical crack in the molded part of the solenoid body. This crack may be very small and not visible without the use of ATF. Complete instructions for the Shift Solenoid Leak Test can be found in SI Document ID # 856531. If NO visual leaks are found in the TCC enable solenoid, refer to DTC P0894 in the appropriate SI Document. If visual leaks are found in the TCC enable solenoid, continue with the next step. Replace the TCC enable solenoid. Refer to Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness in the appropriate SI Document. Road test the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 06-07-30-007A > Feb > 07 > A/T - MIL ON/DTC P0894/Harsh 1-2 Shift > Page 11353 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11358 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11361 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11362 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11363 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11364 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11365 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11366 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11367 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11368 Vehicle Zoning Strategy TRUCK ZONING Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11369 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11370 Torque Converter Clutch Solenoid: Diagnostic Aids Abbreviations and Meanings Abbreviations and Meanings Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11371 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11372 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11373 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11374 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11375 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11376 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11377 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11378 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11379 Arrows and Symbols Arrows and Symbols This service information uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11380 Conversion - English/Metric (Part 1) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11381 Conversion - English/Metric (Part 2) Decimal and Metric Equivalents Equivalents - Decimal and Metric Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11382 Equivalents - Decimal and Metric 1 Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11383 Equivalents - Decimal and Metric 2 Diagnostic Work Sheets Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Fasteners Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11384 1 - English Bolt, Grade 2 (Strength Class) 2 - English Bolt, Grade 5 (Strength Class) 3 - English Bolt, Grade 7 (Strength Class) 4 - English Bolt, Grade 8 (Strength Class) 5 - Metric Nut, Strength Class 9 6 - Metric Bolts, Strength Class Increases as Numbers Increase The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: ^ Lower strength ^ No numbered head marking system ^ Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: ^ M6.0 X 1 ^ M8 X 1.25 ^ M10 X 1.5 ^ M12 X 1.75 ^ M14 X 2.00 ^ M16 X 2.00 Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. 1 - Prevailing Torque Nut, Center Lock Type Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11385 2 - Prevailing Torque Nut, Top Lock Type 3 - Prevailing Torque Nut, Nylon Patch Type 4 Prevailing Torque Nut, Nylon Washer Insert Type 5 - Prevailing Torque Nut, Nylon Insert Type 6 Prevailing Torque Bolt, Dry Adhesive Coating Type 7 - Prevailing Torque Bolt, Thread Profile Deformed Type 8 - Prevailing Torque Bolt, Nylon Strip Type 9 - Prevailing Torque Bolt, Out-of-Round Thread Area Type A prevailing torque fastener may be reused ONLY if: ^ The fastener and the fastener counterpart are clean and not damaged ^ There is no rust on the fastener ^ The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11386 Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Note in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11387 - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11388 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(r)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics . - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics . TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories . - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to test probe notice in service precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 . The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light Probe Kit NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO .64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11403 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11404 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11405 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11406 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11407 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11408 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11409 Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11410 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11411 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11412 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11413 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11414 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11415 CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11416 TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation . GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11417 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11418 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11419 shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11420 - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11421 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11422 terminal package. The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11423 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11424 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Special Tools Ordering Information Special Tools Ordering Information The special service tools shown in this service information that have product numbers beginning with J or BT are available for worldwide distribution from: Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A. 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 a.m.-7:00 p.m. Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7375 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A. 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 a.m.-6:00 p.m. EST Fax: 1-586-578-7205 Thread Inserts Thread Inserts Repair Procedure ^ Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. 1. Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Important: The insert should be flush to one turn below the surface. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training Training General Motors makes available automotive classroom training through the GM Training Centers and colleges. GMCL (General Motors of Canada Ltd) Dealers Course scheduling for GMCL Training Centres, remote and college locations is determined by Dealer Training Needs requested in TAMS (Technician Activity Monitoring System). Dealers register their Training Needs electronically via DCS. Training is then scheduled when sufficient Needs are received to support minimum classroom attendance. Dealers who have entered Needs will receive invitations via DCS (Dealer Communication System) to attend the requested training. Dealers having questions concerning the GMCL training process can directly contact GMCL Training Co-ordinators via toll free numbers 1-800-263-9555 (English) or 1-800-263-9770 (French). Fleets GMCL Fleet Training is accomplished through a separate training organization in Canada. Fleets can request training by faxing a document contained in a GMCL brochure (Fleet Training - Your Competitive Advantage) distributed to fleets (FAX # 905-831-1598). Further information concerning Fleet training can be obtained by calling toll free to 1-888-456-6660. United States Dealers All US Dealers enroll through the GM Enrollment Calling Center (EEC). Each GM Dealer has an assigned consultant that calls the Service Manager each month. During this consultation call, the EEC processes enrollments requested by the Dealer Service Manager. Technicians should advise their Service Manager of the training they need, course names, and course numbers for the classes the want to attend. Fleets Fleets are to call their GM Training Center. Non-GM Dealer Technician Technician training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. GM Training Center course availability and schedules can be obtained by calling 1-800-825-5886. Clinics are offered through AC Delco Warehouse Distributors. Contact yours directly. Correspondence courses are available on batteries, spark plugs and filters. These courses can be obtained through any AC Delco Representative or AC Delco Warehouse Distributor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 Torque Converter Clutch Solenoid: Connector Views Automatic Transmission Internal Connector End Views (M30/M32) Automatic Transmission Internal Connector End Views (M30/M32) Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Automatic Transmission Internal Connector End Views (M33 Only) Automatic Transmission Internal Connector End Views (M33 Only) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 Torque Converter Clutch Pulse Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated Solenoid Valve, Wiring Harness Side Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 11436 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 4L80-E/4L85-E - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Clutch Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the 1-2 accumulator, if necessary. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11439 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11440 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11441 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. Important: Removal of the valve body is not necessary for the following procedure. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11442 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11443 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11444 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the pressure control solenoid (377). Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11445 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11446 Torque Converter Clutch Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11447 accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. Important: ^ When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. ^ The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). ^ Tighten the bolts to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11448 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. ^ Tighten the bolts to 12 Nm (108 inch lbs.). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and Main MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11449 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. 6. Remove the TCC PCS retaining bolt and retaining bracket. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11450 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. ^ Tighten the bolt to 12 Nm (108 inch lbs.). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 11455 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 11456 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 11457 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 11458 Disclaimer Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission Transmission Cooler: Service and Repair 4L80-E/4L85-E - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hoses from the auxiliary cooler. 3. Remove the auxiliary oil cooler bolts (1). 4. Remove the auxiliary oil cooler push pins (2) 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. 2. Install the bolts (1) to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the push pins (2) to the radiator brace. 4. Connect the transmission oil cooler lines to the auxiliary cooler. 5. Install the grille assembly. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission > Page 11461 Transmission Cooler: Service and Repair Allison - Automatic Transmission Transmission Fluid Cooler Connector Replacement Transmission Fluid Cooler Connector Replacement Removal Procedure 1. Disconnect the hose from the transmission oil cooler pipe connector being replaced. 2. Remove the transmission oil cooler pipe connectors (1) and (2). Installation Procedure 1. Install new transmission oil cooler pipe connectors (1) and (2). ^ Tighten to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the hose to the transmission oil cooler pipe connectors. Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L80-E/4L85-E - Automatic Transmission > Page 11462 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. 5. Check and add transmission fluid as necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Tow/Haul Switch: Locations Automatic Transmission Electronic Component Views Transmission Control Module (MW7) Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Engine Harness to Transmission Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 11466 Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Tow/Haul Switch: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11469 Tow/Haul Switch: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Tow/Haul Switch, Column Wiring Harness Side Tow/Haul Switch, Column Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11470 Tow/Haul Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Transmission Internal Mode Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > Page 11471 Tow/Haul Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11476 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11477 Transmission Mount: Service and Repair 4L80-E/4L85-E - Automatic Transmission Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11478 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11479 Transmission Mount: Service and Repair Allison - Automatic Transmission Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11480 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Model Only 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 11484 Vehicle Speed Sensor (VSS) 1 - VSS Sensor - Model Dependent 2 - Transfer Case Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 11485 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Transmission Range Switch, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11488 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range (TR) Switch Connector, Wiring Harness Side Transmission Range (TR) Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11491 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11494 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11495 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11496 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11497 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Install the PNP switch bolts finger tight. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11498 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11499 can not be obtained, replace the switch. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair Transmission Pressure Test Port: Service and Repair Oil Pressure Test Plug Replacement Removal Procedure 1. Remove the pressure tap plug (2) and O-ring (1) on the bottom of the converter housing near the transmission external oil filter. 2. Remove the O-ring from the plug and discard it. Installation Procedure 1. Install a new O-ring (1) on the pressure tap plug (2). 2. Install the plug and O-ring into the converter housing. ^ Tighten the plug to 12 Nm (108 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair > Page 11503 Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11508 Transmission Speed Sensor: Locations 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Vehicle Speed Sensor Assembly, Wiring Harness Side Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11511 Transmission Speed Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11512 Automatic Transmission Output Speed Sensor (OSS) Automatic Transmission Output Speed Sensor (OSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11513 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Input Speed Sensor (AT ISS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11514 Automatic Transmission Turbine Speed Sensor Automatic Transmission Turbine Speed Sensor Vehicle Speed Sensor (VSS) Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11517 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11518 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11519 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11520 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11521 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11522 Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure 1. Be sure the vehicle ignition is turned off. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 11523 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Install the speed sensor bolt (1). ^ Tighten bolt to 12 Nm (108 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 1500 2wd Workshop Manual (V8-4.8L VIN V (2006)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Temperature (TFT) Sensor Specifications